High-performance far-infrared surface heating element of carbon composite material and application thereof
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Solution Overview
Problem
Current carbon composite surface heating elements face issues with high conductive resistance, low power density, vulnerability to cracking, and degradation under harsh conditions, leading to inefficient heating and safety concerns.
Innovation Solution
A high-performance far-infrared surface heating element using a carbon composite material with an sp2 hybrid structure, featuring low surface resistance, high power density, and a thermal stable electronic insulating layer for improved durability and safety, capable of maintaining conductivity and strength even after repeated bending and exposure to harsh conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional carbon composite materials are used for surface heating elements, then the heating element can be made lightweight and flexible, but the conductive resistance is high resulting in low power density
Solution Approach 1:
The patent uses a composite structure combining carbon nanotubes with polymer matrices (epoxy resin, polyimide, or polyester) to create a material that maintains flexibility while significantly improving electrical conductivity. The carbon nanotubes form a conductive network within the polymer, reducing conductive resistance and increasing power density compared to conventional carbon composites.
Solution Approach 2:
The patent optimizes the alignment and orientation of carbon nanotubes through specific processing methods to enhance electrical conductivity in the heating direction. By controlling the spatial arrangement and density of carbon nanotubes, the material achieves lower resistance and higher power density while maintaining its flexible nature.
2Ease of operation
If carbon composite heating films are made thin and flexible for easy installation, then the heating element is easy to install and conform to surfaces, but the film cracks after repeated bending
Solution Approach 1:
The patent employs a composite structure where carbon nanotubes are embedded in a flexible polymer matrix. This combination provides both flexibility for easy installation and structural integrity to prevent cracking during repeated bending. The polymer matrix acts as a protective medium that maintains the mechanical strength of the thin film.
Solution Approach 2:
The patent creates a thin-film heating element that can be easily installed on various surfaces while maintaining sufficient mechanical strength. The flexible polymer-based composite structure allows the film to bend repeatedly without cracking, solving the contradiction between thin-film flexibility and structural durability.
3Ease of manufacture
If simple structure heating films are used for cost-effectiveness, then the manufacturing process is simple and cost is reduced, but the heating film degrades under harsh conditions such as damp heat and thermal shock
Solution Approach 1:
The patent uses a composite structure with carbon nanotubes and environmentally stable polymers (epoxy resin, polyimide, or polyester) that resist degradation under harsh conditions. These polymers provide excellent resistance to damp heat, ultraviolet light, salt mist, and thermal shock, while the manufacturing process remains relatively simple and cost-effective.
Solution Approach 2:
The patent selects and optimizes polymer materials with specific thermal and environmental stability parameters to ensure the heating film maintains its performance under harsh conditions. By carefully choosing polymers with appropriate glass transition temperatures, thermal conductivity, and chemical resistance, the film achieves high reliability without significantly complicating the manufacturing process.
4Power
If high voltage is used to achieve rapid heating in underfloor heating applications, then the heating power is sufficient (50-250 W/m2), but the system requires complex circuit protection modules
Solution Approach 1:
The patent reduces the operating voltage of the heating element by improving the electrical conductivity of the carbon nanotube composite material. This voltage reduction decreases the risk of electrical hazards and eliminates the need for complex circuit protection modules, while the enhanced material conductivity ensures sufficient heating power is still achieved at the lower voltage.
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 flexible, high-strength, and stable heating element with efficient heat conversion, achieving up to 99% thermal efficiency, safe operation at low voltages, and enhanced resistance to environmental stressors, eliminating the need for circuit protection modules and ensuring safety and environmental friendliness.
Implementation Method 1
The surface heating element is a far-infrared surface heating element formed by applying parallel electrodes at both ends and insulating as a whole using a conductive material such as graphite, graphene, carbon fiber, carbon nanotubes, and fullerene as a surface heat source
Implementation Method 2
the surface heating element of carbon material is heated by far-infrared radiation, and the heating effect is better
Data Source
AI summary
The present application discloses a high-performance far-infrared surface heating element of carbon composite material and application thereof. The surface heating element comprises: a carbon composite material layer comprising a film-like material consisted of an sp2 hybrid structure carbon material; and thermal stable electronic insulating layer provided on opposite sides of the carbon composite material layer. The surface heating element of the present application has the characteristics of flexibility, high strength, high stability, high safety, etc., and has excellent flame retardancy, no harmful electromagnetic, no circuit protection module, economical, safe and practical characteristics, and no safety hazard; it can be used as a direct surface heating source in the field of low-voltage electric heating, such as a civil heating device used in the preparation of a floor heating device, an electric heating carpet, an electric heating mattress or a heater, as well as an industrial heating device for lithium battery modules and industrial pipe heating elements.