EP2740146B1 - Verfahren zur herstellung eines elektrisch leitenden materials, elektrisch leitendes material sowie strahler mit elektrisch leitendem material - Google Patents

Verfahren zur herstellung eines elektrisch leitenden materials, elektrisch leitendes material sowie strahler mit elektrisch leitendem material Download PDF

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Publication number
EP2740146B1
EP2740146B1 EP12734807.6A EP12734807A EP2740146B1 EP 2740146 B1 EP2740146 B1 EP 2740146B1 EP 12734807 A EP12734807 A EP 12734807A EP 2740146 B1 EP2740146 B1 EP 2740146B1
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EP
European Patent Office
Prior art keywords
electrically conductive
carbon
fibers
conductive material
matrix
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EP12734807.6A
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German (de)
English (en)
French (fr)
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EP2740146A2 (de
Inventor
Sven Linow
Maike Klumpp
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Heraeus Noblelight GmbH
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Heraeus Noblelight GmbH
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Publication of EP2740146A2 publication Critical patent/EP2740146A2/de
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01K—ELECTRIC INCANDESCENT LAMPS
    • H01K1/00—Details
    • H01K1/02—Incandescent bodies
    • H01K1/04—Incandescent bodies characterised by the material thereof
    • H01K1/06—Carbon bodies
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01K—ELECTRIC INCANDESCENT LAMPS
    • H01K3/00—Apparatus or processes adapted to the manufacture, installing, removal, or maintenance of incandescent lamps or parts thereof
    • H01K3/02—Manufacture of incandescent bodies
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/0033—Heating devices using lamps
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/10—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor
    • H05B3/12—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor characterised by the composition or nature of the conductive material
    • H05B3/14—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor characterised by the composition or nature of the conductive material the material being non-metallic
    • H05B3/146—Conductive polymers, e.g. polyethylene, thermoplastics
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/017—Manufacturing methods or apparatus for heaters

Definitions

  • the present application relates to a method for producing an electrically conductive material, an electrically conductive material and a radiator, which includes an electrically conductive material.
  • the electrically conductive materials in question come in particular as electrically heated elements for use in incandescent or infrared radiators into consideration. Accordingly, such electrically conductive materials are particularly suitable for the targeted emission of rays in the visible and especially in the non-visible wavelength range.
  • electrically conductive materials are often carbon-based or consist predominantly of carbon. Electrically conductive materials of the type in question may, however, alternatively or additionally comprise materials other than carbon as starting material which provide electrical conductivity.
  • electrically conductive materials in question may also be referred to as filament, filament, filament, heating rod and in particular as filament. If filaments are mentioned below, the electrically conductive material from which the filament is constructed is always included.
  • electrically conductive materials in particular of carbon-based materials, for use as an electrically heated element for use in incandescent lamps or infrared radiators has long been known.
  • electrically conductive materials undergo a variety of fabrication steps designed to prepare the materials for permanent use at temperatures in excess of 800 ° C.
  • the electrical properties are generally adjusted so that the desired performance (infrared radiation) or the color temperature (incandescent lamps) are achieved at a given rated voltage and given dimensions of the radiation source.
  • the electrically conductive material should have sufficient mechanical strength and dimensional stability.
  • the effort and cost of producing the electrically conductive material should be within a reasonable range.
  • electrically conductive materials will generally vary the requirements shown above, and various technical solutions to comply with these requirements will be selected by the competent expert.
  • An overview of the production of said electrically conductive materials is thereby John W. Howell, Henry Schroeder: History of the Incandescent Lamp, The Maqua Company, Schenectady, NY 1927 , removable.
  • said electrically conductive materials can be produced by surrounding fibers which have an electrical conductivity with a suitable surrounding material.
  • This surrounding material can then provide a suitable matrix for the electrically conductive fibers, in particular after a heat treatment has been carried out.
  • an electrically conductive material may be made of crystalline carbon, amorphous carbon, and other conductivity adjusting substances, such as nitrogen and / or boron US 6,845,217 B2 described.
  • US 6,627,144 suggests the use of organic resin, carbon powder, silicon carbide and boron nitride.
  • electrically conductive material produced in these ways has the property that filaments or heating rods obtained therefrom must not fall below a certain not inconsiderable thickness. Furthermore, the length of such filaments or heating rods is limited to the top. However, the cross section of the filaments resulting from these mechanical requirements results in high conductivity with a low surface area. In addition, the low mechanical stability of such filaments makes industrial processing difficult or even impossible.
  • electrically conductive materials for lamps or radiators based on fibers or fibrous material.
  • small thicknesses of the assembled electrically conductive material for example, as a filament or heating rod
  • Such filaments are usually produced by means of a carbonization and optionally a graphitization.
  • the carbonization is usually carried out at temperatures between 400 ° C and 1500 ° C under an inert atmosphere, whereby hydrogen, oxygen and nitrogen and optionally other elements present in particular from the material surrounding the electrically conductive fibers (surrounding material) are eliminated, so that an electrically conductive material produced with high carbon content.
  • the surrounding material becomes the matrix which surrounds the electrically conductive fibers.
  • a graphitization takes place at temperatures between 1500 ° C and 3000 ° C under an inert atmosphere at atmospheric pressure or in a vacuum, after carbonation optionally still existing carbon-free components from the electrically conductive fibers and the surrounding matrix ausasen and thereby the microstructure of the electrically conductive Material is affected.
  • the matrix is understood as meaning the carbonized material surrounding the electrically conductive fibers (i.e., the carbonized surrounding material).
  • the electrical properties of the electrically conductive material can already be influenced during a Grafitmaschines Murphy.
  • the maximum temperature of the graphitization and its duration influence to some extent the conductivity of the resulting electrically conductive material.
  • This effect is in HO Pierson: Handbook of Carbon, Graphite, Diamond and Fullerenes, Noyes Publications, Park Ridge, NJ 1993 described.
  • the high temperatures prevailing in graphitization lower the resistance of the electrically conductive material, this effect is electrically conductive during manufacture Material for long spotlights straight counterproductive, since for long radiators electrically conductive materials with high resistances at high filament temperatures are needed.
  • GB 659,992 proposes a method for reducing the cross section of filaments of a carbon-based electrically conductive material.
  • an etching process in the gas phase is used.
  • this etching treatment is very expensive and involves several additional steps in addition to the carbonation and graphitization step.
  • the present invention has the object to provide an electrically conductive material and a method for its production, which allows the operation of radiators, in particular infrared radiators, of any length at normal mains voltages.
  • the present invention was also based on the object of specifying an electrically conductive material or a method for the production thereof which is suitable for use in emitters, in particular in infrared emitters, and in particular in carbon infrared emitters, and which is in great lengths, ie greater than 0.25 m, preferably greater than 0.5 m, preferably greater than 1.0 m and particularly preferably greater than 2.0 m, can be produced.
  • the present invention has the object to provide an electrically conductive material or a method for its production, which has a higher electrical resistance in otherwise the same configuration (length, diameter) compared to previously known electrically conductive materials.
  • the scrim is formed of carbon fibers and plastic fibers each having a short fiber length.
  • the electrical resistance of the inventively produced electrically conductive material is based primarily on the ratio of the number or the respective mass of the carbon fibers and the plastic fibers, the length of the fibers, in particular the carbon fibers, the orientation of the fibers to each other and the specific number of Points of contact between different carbon fibers within the material.
  • a current flow oriented in any possible current direction forcibly passes through the electrically conductive material at least in regions through the matrix, which at least partially surrounds the electrically conductive fibers.
  • the electrical properties of the electrically conductive material can be varied in a previously unattainable manner for a very targeted and accurate and on the other in a surprisingly wide range.
  • a targeted and precise selection of the matrix material which has an electrical conductivity, can result in a very precise and reproducible design of the electrical properties of the electrically conductive material.
  • a matrix material having a rather low or else a high electrical conductivity can be selected.
  • the matrix material arises from the carbonization of the plastic fibers used for the preparation of the mixture.
  • An electrically conductive material according to the invention comprises on the one hand a base material which is suitable for further processing and / or shaping.
  • the term of the electrically conductive material in the context of the invention also includes materials that have already undergone a particular confectioning, and in particular also includes a filament, a filament, a filament, a heating rod, or the like.
  • the electrically conductive material may already have electrical connections.
  • the electrically conductive material of the invention relates to materials or filaments, in particular flat filaments, for light radiators, in particular lamps or infrared radiators whose filament temperature significantly exceeds the oxidation limit of carbon in air, and which therefore in vacuum or be operated under a protective atmosphere, in particular under argon.
  • a clutch in the sense of the present application describes a mixture of a multiplicity of individual threads, namely fibers, which are deposited randomly in comparison to braiding or weaving.
  • Such a fabric arises in particular in the mixing and depositing of different threads or fibers, each with a short length.
  • fabrics are generally formed by passing one or more weft yarns through a series of warp yarns.
  • warp and weft threads are at an angle of about 90 ° to each other.
  • at least three threads are laid around each other. As a rule, these are at least three threads in an angle deviating from about 90 ° to each other. In comparison to weaving and braiding, however, there is no guidance of the monofilament.
  • the plastic fibers can also be referred to as surrounding material which surrounds the carbon fibers.
  • This surrounding material can coat, bind, hold or impregnate the carbon fibers.
  • the mixture in the form of a sheet-like compound of the carbon fiber and the plastic fiber, in particular in a consolidated form, can also be referred to as a composite of carbon fibers and synthetic fibers.
  • the carbon fibers are also referred to below as electrically conductive fibers. These terms are used synonymously.
  • a consolidation of the mixture in the sense of the application describes a mechanical consolidation or compaction of the mixture of the carbon fiber and the plastic fiber.
  • the consolidation can be accompanied by a heat effect. Consolidation can be accomplished, for example, by rolling or heating the mixture, or both.
  • Carbonizing the mixture to convert the plastic fibers into a carbon-based, electrically conductive matrix involves high temperature treatment of the consolidated mixture in a temperature range of 600 ° C to 1500 ° C. Particularly preferred is a temperature range of 800 ° C to 1200 ° C.
  • a carbon-based matrix which has an electrical conductivity is formed from the plastic fibers or from the surrounding material. The matrix at least partially surrounds the carbon fibers which undergo substantially no conversion during the carbonation step.
  • carbonization can be followed by graphitization. Both process steps have already been explained above.
  • a possible current direction or current flow direction through the electrically conductive material initially describes any direction in which current can be conducted through the electrically conductive material according to the invention.
  • a preferred current flow direction preferably relates to a longitudinal direction of extension of the electrically conductive material.
  • Such a longitudinal extension direction can coincide in particular with the longitudinal axis of a radiator housing into which the electrically conductive material, in particular as a filament, can be introduced.
  • the electrically conductive material is helical or meander-shaped, so that in this regard a longitudinal direction of the electrically conductive material may differ from a longitudinal axis of a surrounding housing.
  • a possible current flow direction relates to the longitudinal direction of a filament.
  • the mass fraction of carbon fibers based on the mixture is 1 mass% (wt .-%) to 70 wt .-%.
  • the mass fraction is preferably 30% by mass to 60% by mass, particularly preferably 45% by mass to 55% by mass.
  • the mixture has a fiber surface weight of 75 g / m 2 to 500 g / m 2 . Particular preference is given to a fiber surface weight of 120 g / m 2 to 260 g / m 2 .
  • This information on preferred fiber surface weights refers to a not yet carbonized but already consolidated mixture.
  • a refinement of the method proves to be expedient, wherein within the mixture the carbon fibers and the synthetic fibers differ in their length by at most 50%, based on the length of the carbon fibers.
  • the carbon fibers and the plastic fibers differ in length by a maximum of 10%, particularly preferably by not more than 5%, in each case based on the length of the carbon fibers.
  • the respective fiber length is to be understood as an average fiber length of the respective species, which can be determined by known statistical methods.
  • the same length as possible of carbon fibers and synthetic fibers initially facilitates the production of a homogeneous mixture.
  • the electrical properties of the subsequently produced electrically conductive material are better adjustable under this condition and thus more accurately predictable.
  • the carbon fiber or the plastic fiber or both have a fiber length of 3 mm to 30 mm within the mixture. Preference is given to a fiber length in a range of 10 mm to 25 mm, and particularly preferably in a range of 15 mm to 20 mm.
  • a better miscibility of the components as well as a precise adjustability of the electrical properties of the electrically conductive material produced later are likewise obtained.
  • the carbon fiber is preferably obtained from polyacrylonitrile (PAN), tar or viscose, or a mixture of at least two thereof.
  • PAN polyacrylonitrile
  • the carbon fiber preferably has a PAN-based fiber and / or a fiber without coating the surface. If the surface is coated, a coating is preferred which leaves a carbon residue upon further carbonization, but at least does not damage the carbon fiber.
  • thermoplastic material includes a thermoplastic material.
  • the proportion of thermoplastics on the plastic fiber is preferably at least 40% by mass, preferably at least 80% by mass, and particularly preferably at least 95% by mass, in each case based on the total mass of the plastic fiber.
  • a plastic fiber, which has thermoplastic components or consists entirely of thermoplastics, proves to be particularly suitable for mixing with a carbon fiber and for producing a flat Geleges. Furthermore, high carbon content is achieved from thermoplastics after carbonization. The thermal consolidation of mixtures comprising thermoplastics is also facilitated.
  • the thermoplastic may include polyethersulfone (PES), polyetheretherketone (PEEK), polyetherimide (PEI), polyethylene terephthalate (PET), polyphthalamide (PPA), polyphenylene sulfide (PPS) or polyimide (PI), or a mixture of at least two thereof. Particularly preferred are PEEK and / or PET, which provide a high carbon content after carbonization.
  • thermosetting plastic is used in addition to the plastic fiber made of thermoplastic material.
  • This thermosetting plastic may preferably include a vinyl ester resin, a phenolic resin or an epoxy resin, or a mixture of at least two thereof.
  • the electrically conductive material is produced with a carbon content of at least 95% by mass.
  • a preferred carbon content is in particular more than 96% by mass, particularly preferably more than 97% by mass.
  • a preferred upper limit for the carbon content is 99.6% by mass.
  • the matrix has a lower specific electrical conductivity than the electrically conductive fibers.
  • the matrix has a specific conductivity of at least 5, preferably at least 10, lower than that of the electrically conductive fibers.
  • a preferred embodiment of the method provides for the use of carbon fibers, in particular of PAN-based carbon fibers, which at room temperature has a specific electrical resistance of 1.0 ⁇ 10 -3 to 1.7 ⁇ 10 -3 ⁇ cm, particularly preferably of 1 , 6 x 10 -3 ⁇ cm.
  • the use of plastic fibers is preferred which have a resistivity of more than 10 7 ⁇ cm, more preferably of more than 10 16 ⁇ cm, at room temperature. From these synthetic fibers, the matrix having electrical conductivity is produced in a subsequent step of the method according to the invention.
  • thermoplastic and / or thermosetting parts are preferred.
  • further fillers such as inorganic particles, preferably oxides, sulfates or aluminates, or mixtures thereof, may be added.
  • the plastic fiber comprises a thermoplastic material as surrounding material and basis for the matrix.
  • the surrounding material may also comprise a thermosetting material.
  • the scrim is again deformed by heating prior to carbonization and deformed, in particular by pulling and / or stretching in the plane of the Geleges and / or by deformation perpendicular to the plane of the Geleges and / or by twisting the Geleges ,
  • a targeted influencing of the electrical and / or mechanical properties of the subsequently produced electrically conductive material is made possible.
  • the scrim may be reinforced by at least one layer of carbon fibers prior to carbonization, in particular prior to trimming or consolidation or drying.
  • the material may be reinforced by at least one carbon fiber roving prior to carbonization, in particular prior to trimming or consolidation or drying.
  • Carbon fiber rovings are bundles of carbon fibers, which preferably have very long lengths. Furthermore, rovings are preferably non-twisted fiber bundles. Commercially available rovings are offered for example with 12000, 3000 and more rarely with 1000 fibers per roving. The diameter of a single carbon fiber is generally about 5 microns to about 8 microns.
  • the scrim is thermally consolidated prior to strengthening with at least one layer or at least one roving of carbon fibers, and is re-thermally consolidated after strengthening and before carbonization.
  • an embodiment of the method is proposed in which carbon is removed from the electrically conductive material.
  • This removal process preferably takes place after the completion of the electrically conductive material.
  • a treatment of the electrically conductive material with a reactive fluid, in particular hydrogen and / or water vapor.
  • a protective gas can be used in the treatment, preferably argon.
  • an electrically conductive material obtainable by a process according to the present invention.
  • This electrically conductive material can serve in particular for the generation of infrared radiation, and is particularly suitable for the provision of filaments, filaments, incandescent filaments, incandescent filaments or heating rods as radiation sources, in particular for infrared radiators. Reference is made to the statements relating to the method according to the invention.
  • Particularly preferred is an embodiment in which more than 40% of the carbon fibers passing through the cutting plane do not contact any further carbon fiber extending through the same cutting plane.
  • the indication of the proportion of those carbon fibers which contact no further extending through the same sectional plane carbon fiber is a measure of the electrical resistivity of the electrically conductive material.
  • the electrical properties of the electrically conductive material are adjustable in a wide range and with considerable accuracy.
  • the proportion of contacting carbon fibers can be determined by statistical methods. In this case, microscopic sectional photographs of the electrically conductive material can be used.
  • a said cutting plane is defined by the electrically conductive material so that the cutting plane is oriented orthogonal to a possible current flow direction through the material.
  • the concept of a possible current flow direction through the electrically conductive material has already been defined. It is expedient, in particular, to determine a cutting plane, which is oriented orthogonal to a longitudinal direction of the electrically conductive material, in particular wherein the electrically conductive material is elongate, preferably as a filament, is formed.
  • an electrically conductive material which has several of the above-mentioned properties, very particularly preferred is a material which has all of these properties.
  • the electrically conductive material according to the invention can also be produced directly as a filament which already has electrical end contacts.
  • the plastic fiber has a thermoplastic plastic
  • the following partial method is proposed: a) cutting the slip, b) attaching the electrical end contacts, c) carbonization, d) graphitization. Subsequently, the filament can be processed to a spotlight.
  • the plastic fiber has a thermosetting plastic
  • the following partial method is preferred: a) cutting the slip, b) attaching the electrical end contacts, c) optionally oxidation, d) carbonization, e) graphitization. Subsequently, the filament can be processed to a spotlight.
  • the electrically conductive material arranged in the radiator can in particular be made up as a filament and / or in the form of a filament, a filament, a filament, a heating rod or a heating plate.
  • a radiator in which the electrically conductive material has such flexibility that it is circular and bent over its entire length by a radius of 1.0 m, preferably less than 1.0 m, particularly preferably 0.25 m can be without causing breakage of the carbon fibers and / or the matrix and / or separation of carbon fibers and the matrix.
  • the electrically conductive material should have the tendency to return after bending in the embossed stretched shape.
  • the emitter may comprise an electrically conductive material which has an electrical conductivity, measured as the electrical operating voltage per length of the electrically conductive material, in particular of the filament, in a range greater than 150 V / m, preferably greater than 300 V / m.
  • FIG. 1 schematically shows a greatly enlarged sectional view of a mixture 1 in the form of a sheet 2, wherein the mixture 1 within a preferred embodiment of the method according to the invention embodies a precursor of the inventively available electrically conductive material.
  • the sheet-like scrim 2 is a mixture 1 of substantially randomly deposited carbon fibers 3 (shown filled) and plastic fibers 4 (shown in outline), which each have a short fiber length in the range between about 3 mm to about 30 mm.
  • the carbon fibers 3 and the plastic fibers 4 differ in their length by a maximum of 50%, based on the length of the carbon fibers 3.
  • the plastic fibers 4 in this case contain a thermoplastic material.
  • a thermoplastic material In particular PEEK and / or PET is preferred.
  • consolidation of the mixture 1, namely the sheet 2 takes place after a possibly necessary drying step. Thereafter, the mixture 1 can preferably have a fiber area weight of 75 g / m 2 to 500 g / m 2 have.
  • carbonization of the mixture 1 is then carried out, wherein the carbonized plastic fibers 4 are converted into a carbon-based, electrical conductivity-containing matrix which at least partially surrounds the carbon fibers 3.
  • This matrix is formed only in the inventively available, electrically conductive material and therefore in Fig. 1 not yet shown.
  • FIG. 2 On the other hand, in a likewise schematic, greatly enlarged sectional view shows a detail of a preferred embodiment of the electrically conductive material 5 according to the invention, which is obtainable by a preferred embodiment of the method according to the invention.
  • the carbon fibers 3 are still shown as filled in.
  • the carbon fibers of the plastic fibers have been used to form a carbon-based matrix 6 containing electrical conductivity, which surrounds the carbon fibers 3. Therefore, the plastic fibers are in Fig. 2 not shown anymore.
  • the electrically conductive material 5 according to the invention is formed in this example as filament 7, of which a middle section is shown.
  • the electrically conductive material 5, namely the filament 7, extends in a longitudinal direction 8, which coincides with the direction of current flow 9 during later operation of the filament 7.
  • the electrical properties of the electrically conductive material 5 are determined inter alia by the length of the carbon fibers 3 and / or the plastic fibers 4 (s. Fig. 1 ), the orientation of the carbon fibers 3, the mass ratio of the fibers 3, 4, the defined specific electrical conductivity of carbon fibers 3 and matrix 6 and the specific number of points of contact 10 between different carbon fibers 3 within the matrix 6.
  • a cutting plane 11 is arbitrarily determined by the electrically conductive material 5.
  • the sectional plane 11 is expediently oriented orthogonal to a possible current flow direction 9.
  • the current flow direction 9 is predetermined by the longitudinal extension direction 8 of the filament 7, so that the cutting plane 11 is oriented orthogonal to the longitudinal direction 8 of the filament 7.
  • FIG. 3 shows a side view of a preferred embodiment of a radiator 12 according to the invention, which is designed here as an infrared radiator.
  • the radiator 12 comprises an electrically conductive material 5, which is formed as an elongate filament 7.
  • the filament 7 is made of an electrically conductive material 5 according to the present invention.
  • the filament 7 is surrounded by a transparent housing 13, which may also be referred to as a cladding tube.
  • a protective gas namely argon.
  • the filament 7 can be operated in the housing 13 under vacuum.
  • the filament 7 is connected by means of contact elements 14 with electrical leads 15. Between the contact elements 14 and the electrical leads 15 each have a spiral compensating element 16 is arranged to compensate for the different thermal expansion of the housing 13 and the filament 7 can.
  • the electrical leads 15 are led out of the housing 13 in a vacuum-tight manner. Crimp connections or any other suitable techniques for vacuum-tight implementation can be used for this purpose.
  • the specified values of the specific electrical resistance refer to a determination by a measuring method according to DIN IEC 60093: 1983; Test method for electrical insulation materials; Specific volume resistance and surface resistivity of solid, electrically insulating materials.
  • the conductivity of the electrically conductive material in the cold state and / or prior to installation in a radiator o.ä. be carried out by means of a resistance measuring device or a conductivity meter, wherein from the determined by means of tape measure or caliper geometric dimensions (length, width, thickness) of the electrically conductive material, in particular as filament, and the measured electrical resistance and the specific electrical resistance (see above) can be calculated ,
  • the electrical resistance of the electrically conductive material incorporated in a radiator and / or during normal operation can be calculated from a measurement of the voltage drop across the radiator and the measurement of the current flowing through the radiator, by Ohm's law. If the geometrical dimensions of the electrically conductive material have also been determined prior to the incorporation of the electrically conductive material into the radiator, then the temperature-dependent value of the specific electrical resistance of the electrically conductive material can also be calculated in this way. This method for calculating the specific electrical resistance is preferred, since in this case the measurement can not be falsified by contact resistances.
  • a determination of the specific electrical conductivity can be carried out by separately measuring the electrically conductive fibers (namely the carbon fibers) before they are used to produce the electrically conductive material and the matrix material (namely the carbonized plastic fibers).
  • the matrix material without electrically conductive fibers can be obtained by, for example, 50 g of the plastic fibers (for example, a thermoplastic polymer) under exclusion of air for about 60 min at about 980 ° C heat treated.
  • the fiber lengths are geometrically determinable before processing into a background. From these values, the average fiber length and the fiber length distribution can be derived. The fiber lengths change by cutting the filaments on average in a predictable manner.
  • the flexibility can be determined by bending the electrically conductive material circularly and over its entire length by a radius, which may preferably have a value of about 0.25 m - 1.0 m.
  • the non-occurrence of fractures of the carbon fibers and / or the matrix and / or the absence of a separation of carbon fibers and the matrix is a measure of the flexibility of the electrically conductive material.
  • electrically conductive materials are considered to be particularly flexible if they can be bent around a circular profile with a radius of 0.25 m. In order to pass the flexibility test at a specific radius, the electrically conductive material should always have the tendency to return to the previously impressed elongated shape.
  • the electrically conductive material here in the form of a filament
  • a so-called non-woven material is first produced, from which then the filaments are cut to the required dimensions.
  • the non-woven material is composed of 3-12 mm length cut carbon fibers and about the same length cut fibers made of a thermoplastic, in this case PEEK together.
  • a thermoplastic in this case PEEK together.
  • PET is also possible, but then, if necessary, a different ratio of carbon fibers to thermoplastic fibers must be selected.
  • the carbon fibers and the plastic fibers are distributed simultaneously and homogeneously on one surface.
  • the uniform distribution is e.g. via a vibrator, which distributes the fibers on an expiring belt.
  • the vibrator preferably has a track width of 300 mm.
  • the carbon fibers and the thermoplastic fibers are preferably a) distributed in a uniform density over the surface, so that a homogeneous distribution of thermoplastic fibers and carbon fibers takes place even on a small scale, and b) distributed in a mixing and mutually overlapping manner on the surface. It should be avoided that distinguishable layers of carbon fibers and plastic fibers on top of each other and not homogeneously mixed.
  • a homogenous distribution which also exists on a small scale means that a homogeneous distribution is preferably present on an area of 10 mm ⁇ 10 mm, preferably 4 mm ⁇ 4 mm.
  • the later electrical properties of the electrically conductive material are defined.
  • the electrical conductivity can u.a. over the basis weight, i. the mass per area of the consolidated material, the number of carbon fiber contact points per unit area, and the volume fraction of plastic fibers in the consolidated mixture. The fewer points of contact of carbon fibers are present to each other and the higher the proportion of plastic fibers, the higher the specific electrical resistance of the electrically conductive material.
  • the consolidated mixture is now dried, if necessary, and then thermally consolidated.
  • the spilled material is first heated, which is preferably done by means of infrared radiation.
  • the proportion of the mixture formed from the synthetic fibers, here consisting of thermoplastics becomes deformable and is compressed directly after the heating process between hot and pressurized rolls.
  • the required filaments are then cut to the desired width and length.
  • these filaments can be provided with electrical leads, are introduced into quartz tubes and these quartz tubes are suitably closed, so that inside the radiator tube formed a protective gas atmosphere, preferably of argon, can be located. Finally, ceramics and electrical leads are attached to the outside as needed. In this regard, merely by way of example, the illustration and description according to Fig. 3 directed.
  • the electrically conductive material here in the form of a filament
  • a so-called non-woven material is first produced, from which then the filaments are cut to the required dimensions.
  • the non-woven material is composed of 3-12 mm length cut carbon fibers and about the same length cut fibers made of a thermoplastic, in this case PEEK together.
  • a thermoplastic in this case PEEK together.
  • PET is also possible, but then, if necessary, a different ratio of carbon fibers to thermoplastic fibers must be selected.
  • the carbon fibers and the plastic fibers are distributed simultaneously and homogeneously on one surface.
  • the uniform distribution is e.g. via a vibrator, which distributes the fibers on an expiring belt.
  • the vibrator preferably has a track width of 300 mm.
  • the carbon fibers and the thermoplastic fibers are preferably a) distributed in a uniform density over the surface, so that a homogeneous distribution of thermoplastic fibers and carbon fibers takes place even on a small scale, and b) distributed in a mixing and mutually overlapping manner on the surface. It should be avoided that distinguishable layers of carbon fibers and plastic fibers on top of each other and not homogeneously mixed.
  • a homogenous distribution which also exists on a small scale means that a homogeneous distribution is preferably present on an area of 10 mm ⁇ 10 mm, preferably 4 mm ⁇ 4 mm.
  • the later electrical properties of the electrically conductive material are defined.
  • the electrical conductivity can, inter alia, on the basis weight, ie the mass per area of the consolidated material, the number of carbon fiber contact points per unit area, and the volume fraction of plastic fibers in the consolidated mixture. The fewer points of contact of carbon fibers are present to each other and the higher the proportion of plastic fibers, the higher the specific electrical resistance of the electrically conductive material.
  • the consolidated mixture is now dried, if necessary, and then thermally consolidated.
  • the spilled material is first heated, which is preferably done by means of infrared radiation.
  • the proportion of the mixture formed from the synthetic fibers, here consisting of thermoplastics becomes deformable and is compressed directly after the heating process between hot and pressurized rolls.
  • the required filaments are then cut to the desired width and length.
  • these filaments are now plasticized by heat and reshaped. So it is possible to draw the band (filament) locally and also to deform it in the plane.
  • desired electrical properties of the later electrically conductive material can be designed in a targeted manner.
  • the ribbon (filament) is subsequently stretched in length so as to allow preferential alignment of the fibers in the longitudinal direction of the ribbon.
  • the resistance of the strip itself is essentially no longer changed, since this is essentially determined by the length of the line route and the number of points of contact between the carbon fibers.
  • the specific filament length electrical power output (typically expressed in W / cm) is varied.
  • the ribbon (filament) is subsequently stretched in width so as to have a preferred orientation of the fibers in the transverse direction to enable the band.
  • the resistance of the tape itself is essentially no longer changed, but the specific power output (typically expressed in W / cm) is changed.
  • a drilled filament is produced.
  • the stretched and heated filament is transferred by means of suitable rollers and guides in a drilled shape in itself.
  • the helical shape can remain stress-free in the material after cooling.
  • the filaments according to embodiments 2.1 and 2.2 are carbonized according to the steps described above in a manner already described in detail.
  • these filaments can be provided with electrical leads, are introduced into quartz tubes and these quartz tubes are suitably closed, so that inside the radiator tube formed a protective gas atmosphere, preferably of argon, can be located. Finally, ceramics and electrical leads are attached to the outside as needed. In this regard, merely by way of example, the illustration and description according to Fig. 3 directed.
  • a non-woven material is produced, which is additionally reinforced with continuous carbon fibers. From this reinforced material then the filaments are cut to the required dimensions.
  • the non-woven material is composed of 3-12 mm length cut carbon fibers and about the same length cut fibers made of a thermoplastic, in this case PEEK together.
  • a thermoplastic in this case PEEK together.
  • PET is also possible, but then, if necessary, a different ratio of carbon fibers to thermoplastic fibers must be selected.
  • the carbon fibers and the plastic fibers are distributed simultaneously and homogeneously on one surface.
  • the uniform distribution is e.g. via a vibrator, which distributes the fibers on an expiring belt.
  • the vibrator preferably has a track width of 300 mm.
  • the carbon fibers and the thermoplastic fibers are preferably a) distributed in a uniform density over the surface, so that a homogeneous distribution of thermoplastic fibers and carbon fibers takes place even on a small scale, and b) distributed in a mixing and mutually overlapping manner on the surface. It should be avoided that distinguishable layers of carbon fibers and plastic fibers on top of each other and not homogeneously mixed.
  • a homogenous distribution which also exists on a small scale means that a homogeneous distribution is preferably present on an area of 10 mm ⁇ 10 mm, preferably 4 mm ⁇ 4 mm.
  • the later electrical properties of the electrically conductive material are defined.
  • the electrical conductivity can u.a. over the basis weight, i. the mass per area of the consolidated material, the number of carbon fiber contact points per unit area, and the volume fraction of plastic fibers in the consolidated mixture. The fewer points of contact of carbon fibers are present to each other and the higher the proportion of plastic fibers, the higher the specific electrical resistance of the electrically conductive material.
  • This non-woven material is now reinforced by one or more carbon fiber layers by applying one or more carbon fiber layers on one or both sides of the non-woven material.
  • a carbon fiber layer is made by passing one or more carbon fiber rovings through a wide, fine comb so that the fibers as much as possible be distributed parallel to each other over a larger area.
  • many fibers are arranged side by side over the width, the thickness resulting from individual or a few superimposed carbon fibers.
  • the mixture is now optionally dried and is then thermally consolidated.
  • the poured material is first heated (preferably by means of infrared radiation) together with the carbon fibers and possibly underlayed, so that the plastic component, here made of thermoplastics, becomes deformable, and is compressed directly afterwards between hot and pressurized rolls.
  • the filaments are then cut to the desired width and length.
  • the further processing is analogous to Embodiment 1, but great care should be taken in parallel alignment of the reinforcing carbon fibers with respect to the pulling direction. Furthermore, the longitudinal cutting should be exactly parallel to the reinforcing carbon fiber rovings.
  • the electrically conductive material here in the form of a filament
  • a so-called non-woven material is first produced, which is additionally reinforced with continuous carbon fibers. From this reinforced material then the filaments are cut to the required dimensions.
  • the non-woven material is composed of 3-12 mm length cut carbon fibers and about the same length cut fibers made of a thermoplastic, in this case PEEK together.
  • a thermoplastic in this case PEEK together.
  • PET is also possible, but then, if necessary, a different ratio of carbon fibers to thermoplastic fibers must be selected.
  • the carbon fibers and the plastic fibers are distributed simultaneously and homogeneously on one surface.
  • the uniform distribution takes place, for example via a vibrator, which distributes the fibers on an expiring belt.
  • the vibrator preferably has a track width of 300 mm.
  • the carbon fibers and the thermoplastic fibers are preferably a) distributed in a uniform density over the surface, so that even a small space homogeneous distribution of thermoplastic fibers and carbon fibers takes place, and b) mixing and distributing each other over the surface. It should be avoided that distinguishable layers of carbon fibers and plastic fibers on top of each other and not homogeneously mixed.
  • a homogenous distribution which also exists on a small scale means that a homogeneous distribution is preferably present on an area of 10 mm ⁇ 10 mm, preferably 4 mm ⁇ 4 mm.
  • the later electrical properties of the electrically conductive material are defined.
  • the electrical conductivity can u.a. over the basis weight, i. the mass per area of the consolidated material, the number of carbon fiber contact points per unit area, and the volume fraction of plastic fibers in the consolidated mixture. The fewer points of contact of carbon fibers are present to each other and the higher the proportion of plastic fibers, the higher the specific electrical resistance of the electrically conductive material.
  • This non-woven material is now reinforced by one or more carbon fiber layers by applying one or more carbon fiber layers on one or both sides of the non-woven material.
  • a carbon fiber layer is made by passing one or more carbon fiber rovings through a wide, fine comb so that the fibers are distributed largely parallel to each other over a larger area. In the carbon fiber layer obtained in this way, many fibers are arranged side by side over the width, the thickness resulting from individual or a few superimposed carbon fibers.
  • the carbon fibers can be used either evenly distributed as thin layers, or targeted as a low fiber rovings are inserted at specific positions.
  • a roving with 12000 fibers per roving (12k roving) it has proven useful to design a roving with 12000 fibers per roving (12k roving) to a width of 60 mm. This achieves an ideal combination of tensile reinforcement of the material and a slight increase in the conductivity of the filament.
  • rovings with 1000 fibers per roving (1k roving) may preferably be designed so that two rovings lie at least the width of the future filament. The distance between the rovings is determined by the geometry of the filament.
  • a roving 2 mm apart and a roving 8 mm apart are inserted from the left edge of the filament. This achieves an ideal combination of tensile reinforcement of the material and still slightly increasing the conductivity of the filament.
  • the mixture is now optionally dried and is then thermally consolidated.
  • the poured material is first heated (preferably by means of infrared radiation) together with the carbon fibers and possibly underlayed, so that the plastic component, here made of thermoplastics, becomes deformable, and is compressed directly afterwards between hot and pressurized rolls.
  • the filaments are then cut to the desired width and length.
  • the further processing is analogous to Embodiment 1, but great care should be taken in parallel alignment of the reinforcing carbon fibers with respect to the pulling direction. Furthermore, the longitudinal cutting should be exactly parallel to the reinforcing carbon fiber rovings.
  • a non-woven material is produced, which is additionally reinforced with continuous carbon fibers. From this reinforced material then the filaments are cut to the desired dimensions.
  • the non-woven material is composed of 3-12 mm length cut carbon fibers and about the same length cut fibers made of a thermoplastic, in this case PEEK together.
  • a thermoplastic in this case PEEK together.
  • PET is also possible, but then, if necessary, a different ratio of carbon fibers to thermoplastic fibers must be selected.
  • the carbon fibers and the plastic fibers are distributed simultaneously and homogeneously on one surface.
  • the uniform distribution takes place, for example via a vibrator, which distributes the fibers on an expiring belt.
  • the vibrator preferably has a track width of 300 mm.
  • the carbon fibers and the thermoplastic fibers are preferably a) distributed in a uniform density over the surface, so that even a small space homogeneous distribution of thermoplastic fibers and carbon fibers takes place, and b) mixing and distributing each other over the surface. It should be avoided that distinguishable layers of carbon fibers and plastic fibers on top of each other and not homogeneously mixed.
  • a homogenous distribution which also exists on a small scale means that a homogeneous distribution is preferably present on an area of 10 mm ⁇ 10 mm, preferably 4 mm ⁇ 4 mm.
  • the later electrical properties of the electrically conductive material are defined.
  • the electrical conductivity can u.a. over the basis weight, i. the mass per area of the consolidated material, the number of carbon fiber contact points per unit area, and the volume fraction of plastic fibers in the consolidated mixture. The fewer points of contact of carbon fibers are present to each other and the higher the proportion of plastic fibers, the higher the specific electrical resistance of the electrically conductive material.
  • the consolidated mixture is now dried, if necessary, and then thermally consolidated.
  • the spilled material is first heated, which is preferably done by means of infrared radiation.
  • the proportion of the mixture formed from the synthetic fibers, here consisting of thermoplastics becomes deformable and is compressed directly after the heating process between hot and pressurized rolls.
  • one or more layers of carbon fibers can now be introduced by passing one or more carbon fiber rovings through a wide, fine comb, so that the fibers are largely distributed parallel to one another over a larger area.
  • the carbon fiber layer obtained in this way many fibers are arranged side by side, the thickness resulting from individual or few carbon fibers arranged one above the other.
  • the further processing is analogous to the embodiment 1, but great care should be taken to a parallel orientation of the reinforcing fibers to the pulling direction.
  • the longitudinal cutting should be exactly parallel to the reinforcing rovings.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Resistance Heating (AREA)
  • Inorganic Fibers (AREA)
  • Reinforced Plastic Materials (AREA)
  • Conductive Materials (AREA)
  • Paper (AREA)
EP12734807.6A 2011-08-05 2012-07-04 Verfahren zur herstellung eines elektrisch leitenden materials, elektrisch leitendes material sowie strahler mit elektrisch leitendem material Not-in-force EP2740146B1 (de)

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DE102011109578.4A DE102011109578B4 (de) 2011-08-05 2011-08-05 Verfahren zur Herstellung eines elektrisch leitenden Materials, elektrisch leitendes Material sowie Strahler mit elektrisch leitendem Material
PCT/EP2012/002800 WO2013020620A2 (de) 2011-08-05 2012-07-04 Verfahren zur herstellung eines elektrisch leitenden materials, elektrisch leitendes material sowie strahler mit elektrisch leitendem material

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KR20140040867A (ko) 2014-04-03
DE102011109578B4 (de) 2015-05-28
HK1199143A1 (en) 2015-06-19
KR101585351B1 (ko) 2016-01-13
WO2013020620A3 (de) 2013-08-22
CN104040682A (zh) 2014-09-10
DE102011109578A1 (de) 2013-02-07
WO2013020620A2 (de) 2013-02-14
EP2740146A2 (de) 2014-06-11
US20140191651A1 (en) 2014-07-10
US9269560B2 (en) 2016-02-23

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