Recyclable Thermoplastic Heating Panel with Conductive Fillers
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Solution Overview
Problem
Conventional plastic processing methods struggle to achieve high electrical conductivity in thermoplastic polymers, making it difficult to produce Joule heating panels with uniform and reproducible heating, and these materials are often not recyclable due to cross-linking or the use of thermosetting coatings.
Innovation Solution
A thermoplastic sheet with conductive particles dispersed using a co-rotating twin-screw extruder, allowing for homogeneous conductivity and recyclability, achieved through specific processing conditions, enabling larger geometries and greater electrode distance, and using thermoplastic materials like polypropylene with additives such as carbon nanotubes, graphite, or graphene.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional plastic processing methods are used to produce thermoplastic polymers, then the manufacturing process is simple and cost-effective, but the electrical conductivity is insufficient for Joule heating applications
Solution Approach 1:
The patent uses composite materials by incorporating conductive fillers (carbon black, carbon nanotubes, graphite, or metal particles) into thermoplastic polymers to create an intrinsically conductive material that combines the ease of thermoplastic processing with sufficient electrical conductivity for Joule heating applications
Solution Approach 2:
The patent changes the electrical parameter of the thermoplastic material by controlling the type, amount, and distribution of conductive fillers during extrusion and molding processes, achieving the required conductivity range (10^-5 to 10^-1 S/m) while maintaining thermoplastic processability
2Reliability
If cross-linking or thermosetting coatings are used to improve heating performance, then the heating efficiency is improved, but the material becomes non-recyclable
Solution Approach 1:
The patent changes the chemical structure parameter by using only thermoplastic polymers without cross-linking or thermosetting agents, maintaining the ability to melt and recycle the material while achieving adequate heating efficiency through optimized conductive filler content and distribution
Solution Approach 2:
The patent enables the material to self-regulate heating through the inherent positive temperature coefficient (PTC) effect of the conductive filler network in thermoplastic matrix, eliminating the need for external control systems while maintaining recyclability
3Reliability
If conductive coatings are applied on substrates to achieve Joule heating, then the electrical conductivity is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent merges the substrate and conductive layer into a single integrated thermoplastic composite material, eliminating separate coating steps and reducing manufacturing complexity while maintaining adequate electrical conductivity for heating applications
Solution Approach 2:
The patent extracts the conductive function from a separate coating layer and integrates it directly into the thermoplastic matrix through filler incorporation, simplifying the overall structure and manufacturing process
4Reliability
If high conductivity is achieved through material composition, then the Joule heating effect is improved, but the resistivity becomes too low requiring closely spaced large electrodes
Solution Approach 1:
The patent optimizes the resistivity parameter to a specific range (10^-5 to 10^-1 S/m) that balances Joule heating efficiency with practical electrode design, achieving effective heating without requiring excessively large or closely spaced electrodes
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 results in a recyclable, lightweight, and self-regulating heating panel with low resistivity, achieving efficient and homogeneous heating with reduced energy consumption and the ability to adapt to various geometries, while ensuring reproducibility and recyclability.
Implementation Method 1
The panel is heated as a result of Joule effect whereby an electrically conductive material is heated when an electric current is applied
Data Source
Figure 1
Figure 2~3
AI summary
The present invention consists of a heating panel which uses, as a power source, electrical energy that is to be converted into thermal energy. To that end, the obtained solution is based on obtaining a sheet (1) of recyclable, lightweight conductive polymer which, as a result of the addition of conductive additives, can change its thermal and electrical properties and replace heat-generating metallic resistors when this type of heating is required. The sheet with conductive particles added as additive forms part of a heatable panel which produces thermal energy when an electric current is applied, such that in order to carry out this process, said panel comprises, in addition to the conductive sheet, metallic electrodes (6) mechanically connected to the sheet, a first temperature-insulating layer (3), a second electricity-insulating layer (2), and a thermocouple sensor (5) attached to the sheet configured for measuring the internal temperature of the heatable panel.