Heating element including nano-material filler
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Solution Overview
Problem
Existing heating elements face challenges in achieving high electrical conductivity and temperature durability due to limitations in material reactivity and sintering requirements, particularly at high temperatures, and struggle with uniform heat distribution in cavities.
Innovation Solution
A heating element comprising a matrix material and nanomaterial filler, such as nano-sheets or nano-rods, which increases electrical conductivity and reduces sintering temperature by forming a percolation network, using materials like silicon oxide, organic polymers, and oxides, borides, or chalcogenides, and manufacturing through coating and heat treatment processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional particulate fillers are used in heating elements, then manufacturing is simpler, but electrical conductivity and heat generation efficiency are insufficient
Solution Approach 1:
The patent changes the dimensional parameters of the filler material from conventional particulate (micrometer scale) to nanoscale dimensions (1-100 nm). This parameter change in size enables the formation of a percolation network at lower filler concentrations, dramatically improving electrical conductivity and heat generation efficiency while reducing the sintering temperature required for processing.
Solution Approach 2:
The patent creates a composite material system combining nanoscale filler particles (such as metal oxides, carbides, or nitrides) with a glass matrix or ceramic binder. This composite structure leverages the high conductivity of the nanofiller while using the matrix material to provide structural integrity and ease of manufacturing, thus resolving the contradiction between improved conductivity and manufacturing simplicity.
2Reliability
If high sintering temperature is used to achieve good heat generation characteristics, then electrical conductivity improves, but energy consumption increases and manufacturing complexity increases
Solution Approach 1:
By changing the size parameter of the filler to nanoscale dimensions, the patent reduces the sintering temperature required to achieve adequate electrical conductivity. The high surface area to volume ratio of nan particles facilitates better contact and percolation network formation at lower temperatures, thereby reducing the energy consumption of the sintering process while maintaining good heat generation characteristics.
3Duration of action of stationary object
If conventional filler materials are used, then manufacturing process is simpler, but temperature durability at high temperatures is reduced due to material reactivity
Solution Approach 1:
The patent employs a composite material system where nanoscale filler particles (such as metal oxides, carbides, or nitrides with high temperature stability) are embedded in a glass matrix or ceramic binder. This composite structure provides temperature durability through the thermally stable nanofiller while the glass or ceramic matrix maintains processability and ease of manufacturing through conventional coating and sintering techniques.
4Ease of manufacture
If rod type heating element is used, then manufacturing is easier, but temperature uniformity in cavities is poor
Solution Approach 1:
The patent transitions from rigid rod-type heating elements to thin film heating elements where the heating composition is coated as a thin layer on a substrate. This thin film configuration allows for better conformality and more uniform heat distribution across the heating surface, improving temperature uniformity in cavities while maintaining ease of manufacture through coating processes.
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 enhances electrical conductivity and reduces sintering temperatures, resulting in improved heat generation characteristics and efficiency, with the nanomaterial filler providing increased sinterability and conductivity compared to traditional particulate fillers.
Implementation Method 1
nanomaterial filler includes at least one of a nano-sheet and a nano-rod... increases electrical conductivity and reduces sintering temperature by forming a percolation network
Implementation Method 2
heating element may be classified as an organic heating element including carbon as a main element... a metal heating element including a metal... the heat generating characteristics thereof are good
Implementation Method 3
heat treating the coating on the substrate to provide the heating element... reduced sintering temperatures... increased sinterability
Data Source
AI summary
A heating element includes a matrix material and a nanomaterial filler, wherein the nanomaterial filler includes at least one of a nano-sheet and a nanorod.