EP2839717B1 - Elektrische heizvorrichtung, bauelement sowie verfahren zu deren herstellung - Google Patents

Elektrische heizvorrichtung, bauelement sowie verfahren zu deren herstellung Download PDF

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Publication number
EP2839717B1
EP2839717B1 EP13719273.8A EP13719273A EP2839717B1 EP 2839717 B1 EP2839717 B1 EP 2839717B1 EP 13719273 A EP13719273 A EP 13719273A EP 2839717 B1 EP2839717 B1 EP 2839717B1
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EP
European Patent Office
Prior art keywords
electrically conductive
conductive component
heating
layer
heating layer
Prior art date
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EP13719273.8A
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German (de)
English (en)
French (fr)
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EP2839717A2 (de
Inventor
Vasily Ploshikhin
Andrey Prihodovsky
Walter Schütz
Stefan Forero
Alexander Ilin
Helmut Bleier
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Futurecarbon GmbH
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Futurecarbon GmbH
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    • 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
    • H05B3/02—Details
    • H05B3/03—Electrodes
    • 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
    • H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
    • H05B3/34—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater flexible, e.g. heating nets or webs
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/131—Wire arc spraying
    • 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
    • H05B3/145—Carbon only, e.g. carbon black, graphite
    • 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
    • H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
    • H05B3/22—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible
    • 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
    • H05B2203/013—Heaters using resistive films or coatings
    • 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
    • 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
    • H05B2214/00—Aspects relating to resistive heating, induction heating and heating using microwaves, covered by groups H05B3/00, H05B6/00
    • H05B2214/04—Heating means manufactured by using nanotechnology
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49082—Resistor making
    • Y10T29/49083—Heater type

Definitions

  • the present invention relates to a component with an electrical heating device and to a method for producing a component.
  • the heating systems currently used as standard are relocatable heating foils or heating wires.
  • polyester films are usually coated with carbon pastes using standard printing processes, Cu contact strips are rolled on at a certain distance along the film strips and the whole thing is laminated in.
  • Some of the flexible material can be purchased on rolls.
  • Heating foils are relatively easy to manufacture, but the restriction to rectangular surfaces and the difficulty of being able to heat complex curved surfaces have a disadvantageous effect.
  • Heating wires are usually laid in a meandering shape so that they fill the area to be heated. This results in the possibility of being able to heat any surfaces, even complex curved / shaped, relatively homogeneously by cleverly laying the wire.
  • a disadvantage is that each new surface geometry requires a separate design.
  • the heating system is designed as a type of parallel connection.
  • these heating systems are only suitable for use on slightly curved, two-dimensional surfaces.
  • the contacting of the heating layer consists of thin metal foils.
  • the WO 01/89265 discloses an electrical resistance heating element having a metal oxide layer with electrical resistance applied directly to a conductive metal substrate.
  • the GB 2 344 042 relates to a method for manufacturing electrical resistance heating elements.
  • the WO 98/51127 describes the manufacture and use of resistance heaters.
  • the DE 10 2009 034 307 discloses a method for producing a high-temperature heater and such a high-temperature heater in which a layer that generates heat when a current flows is provided on a carrier material.
  • the WO 2007/089118 relates to a heating element that uses carbon nanotubes.
  • the WO 2012/159608 describes a composite structure with an ice protection device for an aircraft component for forming a structural element of an aircraft and a production method therefor.
  • the present invention is based on the object of providing a component which has an electrical heating device with which the aforementioned disadvantages can be avoided. Furthermore, a correspondingly improved production method is to be provided.
  • a fundamental feature of the present invention is that a thermal spraying process is used to produce at least one electrically conductive component and to arrange it on the heating layer.
  • Another fundamental feature of the present invention is in particular an electrical heating system with current flow perpendicular to the layer plane and / or with current flow in the direction of the layer plane, which consists of at least one heating layer and at least one electrically conductive component, such as a contacting layer, generated for example by arc spraying , as well as an automatable process for its production.
  • the present invention realizes a new type of construction for an electrical heating system, which is distinguished and distinguished in particular by the following specifications from already existing electrical heating systems:
  • the current flow in the heating system according to the invention takes place in a kind of parallel connection, i.e. perpendicular to the surface the heating layer, and / or in the direction of the plane of the surface of the heating layer.
  • the heating layer is contacted by at least one, for example area-wide, electrically conductive component, for example a contacting layer, which is preferably produced by arc spraying.
  • the heating system according to the invention can be produced on any shaped, complex three-dimensional, for example curved, surface.
  • the heating system according to the invention has a, in comparison with existing Heating systems, high insensitivity to damage.
  • the temperature distribution of the heating system according to the invention is very homogeneous over the entire heating surface. Furthermore, a corresponding production method for such a heating system is specified, which is characterized in particular by the fact that it can be automated to a high degree.
  • a component which has an electrical heating device and a substrate element on which the electrical heating device is arranged, the electrical heating device having at least one first electrically conductive component, at least one heating layer and at least one second electrically conductive component comprises, wherein the first electrically conductive component and / or the second electrically conductive component (a) multilayer system (s) is / are, which is / are thermally sprayed, is / are arranged on the heating layer and a first metallic layer of a Spray material, which has a melting temperature that is a maximum of 300 ° C above the temperature load of the substrate element, and a layer of a further spray material selected from one of copper, brass and aluminum, the heating layer at least partially carbon-based Heating layer out forms and wherein the substrate element is a temperature-sensitive and / or foamed thermoplastic polymer.
  • a multilayer system (s) is / are, which is / are thermally sprayed, is / are arranged on the heating layer and a first metallic layer of a Spray material, which
  • the term arrangement also includes that the conductive component (s) are applied to the heating layer, or else are connected to it.
  • This aspect of the invention particularly relates to the combination of thermal spraying and the heating layer.
  • thermal spraying is a surface coating process.
  • additional materials are melted, partially melted or melted inside or outside a spray gun.
  • the melted particles are accelerated and applied to the surface of the component to be coated, for example spun on.
  • the component surface is not melted and only thermally stressed to a very small extent.
  • the electrically conductive components and the heating layer can be arranged in relation to one another in such a way that a current flow perpendicular to the plane of the heating layer and / or in the direction of the plane of the heating layer is or can be implemented.
  • the electrically conductive components lie in the simplest embodiment on the edges, that is to say the edges, of the heating layer.
  • the heating layer is in particular a heatable coating. If necessary, however, strip-shaped, electrically conductive components can also be attached somewhere within the heating layer.
  • the electrically conductive components for example the electrodes, can be provided over the entire surface below and above the heating layer, so that the electrically conductive components only have to overcome the distance specified by the thickness of the heating layer.
  • An electrical heating device described herein is a device by means of which components that are in contact with the heating device can be heated.
  • the heating device is designed as an electrical heating device. This means that the heating device is operated electrically, with heat being generated in particular due to a current flow.
  • a first and a second electrically conductive component are provided, via which this current flow is realized.
  • the electrically conductive components can for example be metallic, for example as metal layers.
  • a heating layer is also provided, which is designed as a carbon-based heating layer at least in some areas. The invention is not limited to specific embodiments of the electrically conductive components and the heating layer. Some preferred but not exclusive exemplary embodiments are described in more detail below.
  • the electrically conductive components and the heating layer are arranged in a special way. According to the invention, these are arranged in relation to one another in such a way that a current flow perpendicular to the plane of the heating layer and / or in the direction of the plane of the heating layer is or can be realized. This means that a kind of parallel connection is implemented. How this can be done in detail is explained in more detail in the further course of the description using preferred but not exclusive examples.
  • the first electrically conductive component is preferably designed as an electrically conductive contacting layer and / or as an electrically conductive, in particular three-dimensional substrate element.
  • the electrically conductive component can be designed as a metal layer. If the component is designed as a contacting layer, it can be applied, for example, to a substrate element, as described herein. In another configuration, the component itself can be designed as such a substrate element.
  • a substrate element is in particular a carrier element which is suitable for carrying an electrical heating device. In principle, such a substrate element is not restricted to specific sizes and / or shapes.
  • the second electrically conductive component can be designed as an electrically conductive contact-making layer.
  • such an electrically conductive contact-making layer can be embodied in one or more layers. It is only important that the contact-making layer is electrically conductive.
  • One way of specifically reducing mechanical stresses (especially those that occur due to the different coefficients of thermal expansion during manufacture or operation) between the functional layers of the heating device and thus increasing the service life of the heating system is to use the, for example, metallic, contact layers as a multilayer system build from different materials. By selecting suitable materials, both good electrical contact and targeted voltage reduction can be guaranteed.
  • An example is here System made up of the materials copper and zinc or a system made up of the materials copper, tin and zinc.
  • the first electrically conductive component and / or the second electrically conductive component can preferably be designed to cover the entire area. Area-wide means in particular that the contact elements cover or cover at least a partial area of the heating surface.
  • first electrically conductive component and / or the second electrically conductive component can be designed in the form of an electrically conductive contacting pattern.
  • the invention is not limited to specific types and types of patterns. For example, a strip-shaped pattern can be implemented.
  • the contacting layers can be generated or designed as a type of pattern, for example in a meandering manner. This increases the flexibility of the heating system described herein. Furthermore, any differences in the thermal expansion coefficients can be compensated for by this contacting and the resulting mechanical stresses between the functional layers can be reduced or avoided.
  • the functional layers are then in particular the heating layer and the two electrically conductive contacting layers.
  • the electric current can flow between the metal contacts, for example, parallel to the plane of the heating layer.
  • the metal contacts can have, for example, contacting patterns in the form of a comb structure. Current flows here between the webs.
  • a simple variant provides two parallel contacts. Contacts arranged in a ring shape can also be provided.
  • electrically conductive components for example contacting layers, can be designed as rigid or flexible arched / archable surfaces. Floating contacts are also possible.
  • the contacts are parallel. These don't have to be straight. Contacts can be placed under or over the heating layer. Any other geometric arrangement of the contacts requires a local adjustment of the layer thickness of the heating layer, but this is entirely possible, especially with modern printing processes.
  • At least one first and at least second electrically conductive component can be designed as an electrode, the electrodes having different potential levels.
  • a particular embodiment of the invention relates to coatings with a current flow parallel to the layer plane, that is to say in the direction of the layer plane.
  • no full-area electrodes are applied, for example sprayed, but electrode patterns, for example electrode strips.
  • a rectangular area can be equipped by making contact with opposite edges.
  • More complicated surfaces for example surfaces curved in one or two directions with straight or curved edges, can be equipped with optimized electrodes.
  • more than two potential levels are also possible, for example in order to be able to control the specific power independently of one another in different parts of an area.
  • the optimum position and potential level for the electrodes can be determined through experiments and / or simulations.
  • ring-shaped electrodes can also be inserted into this arrangement.
  • Another possible solution can be implemented by two or more electrodes in regular, for example, comb-like geometries. In each of the aforementioned cases, the current flows within the layer plane, i.e. parallel to it, from one electrode to the other.
  • At least one first electrically conductive component and / or at least one second electrically conductive component can preferably be designed in such a way that different temperature ranges and / or heating zones can be or can be implemented in the heating layer.
  • One advantage that results from this embodiment is that the arrangement of the conductive components can influence the flow of heating current in such a way that different temperature ranges or heating zones can be implemented in the surface to be heated.
  • the heating layer is designed at least in some areas as a carbon-based heating layer, in particular as a heating layer based on carbon nanomaterial or carbon micromaterial, for example in the form of a coating or an impregnation. It is also conceivable that some kind of composition of carbon materials with carbon nanomaterials is used. Depending on the configuration, such heating layers consist in particular of a corresponding binder matrix and a carbon formulation tailored to the particular application. Due to the excellent conductivity, high heating outputs can be achieved with harmless low voltage, and in addition, uniform heat radiation can be achieved without so-called hot spots. For example, it can be provided that the heating layer is designed as a plastic doped with carbon material, for example as a polymer doped with carbon nanoparticles.
  • the first electrically conductive component, the heating layer and the second electrically conductive component can be formed like a sandwich.
  • Conductive components designed as conductive contacting layers then serve as area-wide contacting of the heating layer.
  • the sandwich-shaped heating created in this way is characterized in particular by the fact that it can be used on any surface geometry and topology, i.e. also on three-dimensional structures, can be generated. This makes it possible to homogeneously heat even complex-shaped components and structures.
  • the first electrically conductive component, the heating layer and the second electrically conductive component can preferably be connected to one another in such a way that a current flow perpendicular to the coating plane of the heating device, in particular the heating layer, is or can be realized and / or that the first electrically conductive component, the heating layer and the second electrically conductive component are connected to one another in such a way that the electrically conductive components are provided on the sides of the heating layer. In this case, the current flows in the direction of the plane of the heating layer.
  • the contacting of the heating layer by the application of contacting surfaces takes place only on the sides of the surface to be heated.
  • the possibility of providing pipes or pipe-like structures on the inside with a heating layer and of applying the contacting of this heating layer to the open ends of this pipe This allows such structures to be heated easily and efficiently.
  • the first electrically conductive component and / or the second electrically conductive component can preferably have a graded structure.
  • the first electrically conductive component and / or the second electrically conductive component can preferably be applied to the heating layer by means of an application method, in particular by means of an arc spray method to be upset.
  • Arc spraying is a thermal spraying process.
  • other thermal spraying processes can also be used according to the present invention in addition to the arc spraying process.
  • all thermal spraying methods are suitable for producing the electrically conductive component (in particular the first and / or second conductive component, such as the first and / or second contacting layer) of the heating devices described herein and / or the component according to the invention (i.e.
  • the heating system according to the invention insofar as they can be used to process metallic materials and thus produce metallic layers on different substrates (in particular the heating layer of the heating devices described herein and / or the substrate element of the component according to the invention or substrates on which the heating layer or the substrate element is based).
  • substrates in particular the heating layer of the heating devices described herein and / or the substrate element of the component according to the invention or substrates on which the heating layer or the substrate element is based.
  • electrically conductive spray materials in particular are continuously fed to one another at a certain angle. After ignition, an arc burns between the spray materials and melts the spray material.
  • arc spraying is characterized in that two wires are melted inside the so-called spray torch by means of an arc (which can be generated in particular by applying an electric current).
  • the molten particles produced in this way are accelerated by a stream of carrier gas and, after the flight phase, hit the substrate surface to be coated, where the metallic layer is formed by the solidification of the particles.
  • the adhesion mechanism can for the most part be based on mechanical clamping, but in part also on partial welding of the substrate surface and the layer-forming metal particles.
  • the temperature of the molten particles depends on the melting temperature of the material (i.e. spray material) used and to be sprayed during thermal spraying (especially arc spraying) and on the process parameters used and has a direct influence on the temperature load for the substrate to be coated.
  • the process parameters are advantageously set in such a way that damage or destruction of the substrate used (in particular the heating layer of the heating devices described herein and / or the substrate element of the component according to the invention or substrates on which the heating layer or the substrate element is based) during production and / or arrangement the first and / or second conductive component (such as the first and / or second contacting layer) of the heating devices described herein and / or of the component according to the invention is avoided.
  • the process parameters are set in such a way that the temperature load on the substrate remains minimal, in particular that the temperature of the substrate during thermal spraying (in particular arc spraying) is a maximum of 200 ° C (such as ⁇ 195 ° C, ⁇ 190 ° C, ⁇ 185 ° C, ⁇ 180 ° C, ⁇ 175 ° C, ⁇ 170 ° C, ⁇ 165 ° C, ⁇ 160 ° C, ⁇ 155 ° C, ⁇ 150 ° C).
  • Further process parameters that can have an influence on the temperature load of the substrate are the strength of the electric current (with the help of which the arc is generated), the pressure of the carrier gas, the speed of travel (i.e.
  • a low current strength for example 30-100 A, such as 30-95 A, 30-90 A, 30-80 A, 35-75 A, 40-70 A, 45-70 A
  • a medium carrier gas pressure are used for thermal spraying (e.g. 1.0 - 3.0 bar, such as 1.1 - 2.9 bar, 1.2 - 2.8 bar, 1.3 - 2.7 bar, 1.4 - 2.6 bar, 1, 5 - 2.5 bar)
  • a high traversing speed e.g.
  • ⁇ 450 mm / s such as ⁇ 460 mm / s, ⁇ 470 mm / s, ⁇ 480 mm / s, ⁇ 490 mm / s, ⁇ 500 mm / s, ⁇ 510 mm / s, ⁇ 520 mm / s, ⁇ 530 mm / s, ⁇ 540 mm / s, ⁇ 550 mm / s, ⁇ 560 mm / s, ⁇ 570 mm / s, ⁇ 580 mm / s, ⁇ 590 mm / s, ⁇ 600 mm / s) and a spray distance in the range of 50 - 400 mm (e.g.
  • 60 - 390 mm such as 70 - 380 mm, 80 - 360 mm, 90 - 350 mm, 100 - 300 mm, 105 - 290 mm, 110 - 280 mm, 120 - 270 mm, 125 - 260 mm, 130 - 250 mm) are used.
  • the production and / or arrangement of the first and / or second conductive component (such as the first and / or second contact-making layer) of the heating devices described herein and / or the component according to the invention can at an amperage of 30 - 80 A, a carrier gas pressure of 1.5 - 2.5 bar, an overrun speed of> 500 mm / s and a spray distance of 100 - 300 mm.
  • the layer morphology and properties of the layers (in particular metallic layers) produced on the substrate (in particular the heating layer of the heating devices described herein and / or the substrate element of the component according to the invention) by thermal spraying (in particular arc spraying) can furthermore be achieved through the use of various types of carrier gas (for example compressed air , Nitrogen, argon) and / or different nozzle geometries of the spray gun. Special nozzle geometries also enable the use of a so-called secondary gas flow, which mainly affects the size and speed of the molten spray particles.
  • carrier gas for example compressed air , Nitrogen, argon
  • metallic layers with graded properties can advantageously be produced (that is to say produced and / or arranged) on various substrates.
  • first and / or second conductive component such as the first and / or second contacting layer
  • the functional layers of the heating devices described herein and / or the component according to the invention it is possible in a targeted manner reduce mechanical stresses (in particular those that occur due to the different coefficients of thermal expansion during manufacture or operation) between the functional layers of the heating devices described herein and / or the component according to the invention and thus increase the service life of the heating devices described herein and / or the component according to the invention .
  • a particular advantage of the thermal spraying process is the possibility of combining two different spraying materials and thus creating so-called pseudo-alloys.
  • multi-layered layers like the first and / or second conductive component, in particular the first and / or second contacting layer, the heating devices described herein and / or the component according to the invention
  • a smooth transition of the properties between the individual materials such as, for example, between the substrate element and the first conductive component and / or between the first and / or second conductive component and the heating layer).
  • a layer system made of the spray materials copper and zinc is mentioned as an example.
  • a layer of zinc is created as the first layer. This has the function of relieving occurring mechanical stresses.
  • the second layer consists of a so-called pseudo-alloy made of zinc and copper. This is generated (that is, produced and / or arranged) by using different types of spraying materials (for example a wire made of one metal or an alloy and another wire made of another metal or another alloy) at the same time during thermal spraying.
  • a zinc wire and copper wire can be used at the same time to produce a layer of a pseudo-alloy of zinc and copper.
  • a copper layer is created as the third layer of the layer system. In this way, good electrical contact can be guaranteed. It is of course also possible to build up multi-layer systems in this way, which consist of three or more sprayed materials (for example a multi-layer system of one layer each of Zn, Sn and Cu).
  • all conductive materials are suitable as spray materials that can be used in the thermal spray process (in particular the arc spray process), especially those that can be in wire form, such as corresponding metals (for example copper, zinc, tin, aluminum, silver ) or corresponding alloys (e.g. brass).
  • corresponding metals for example copper, zinc, tin, aluminum, silver
  • corresponding alloys e.g. brass
  • Materials that have a high electrical conductivity, such as copper, brass, aluminum or silver, are of course advantageous.
  • the layer thicknesses of the layers produced (that is to say produced and / or arranged) by thermal spraying are in the range of 0.05-0.5 mm.
  • the flexibility of the overall system can also be influenced in this way.
  • Both electrically conductive and electrically insulating materials are suitable as substrates for thermal spraying (especially arc spraying).
  • Electrically conductive materials can be steel, aluminum or copper, for example.
  • Thermoplastic or thermosetting polymers or ceramic materials can be used as electrically insulating materials.
  • the thermal spraying process in particular the arc spraying process
  • the thermal spraying process also allows comparatively low-melting, temperature-sensitive and / or foamed thermoplastic polymers (such as polypropylene (PP), expanded polypropylene (EPP), polystyrene (PS), expanded polystyrene (EPS)) can be provided with metallic layers.
  • PP polypropylene
  • EPP expanded polypropylene
  • PS polystyrene
  • EPS expanded polystyrene
  • the substrate element is a temperature-sensitive and / or foamed thermoplastic polymer.
  • the procedure for coating such temperature-sensitive substrates consists in producing a first metallic layer from a spray material that has a melting temperature of a maximum of 300 ° C (e.g. a maximum of 290 ° C, a maximum of 280 ° C, a maximum of 270 ° C, a maximum of 260 ° C , maximum 250 ° C, maximum 240 ° C, maximum 230 ° C, maximum 220 ° C, maximum 210 ° C, maximum 200 ° C) is above the temperature load of the substrate (e.g. zinc; melting temperature: 419.5 ° C).
  • This first layer serves to protect the substrate material from further temperature effects.
  • a layer of any desired metallic spray material eg copper; melting temperature: 1084.6 ° C.
  • a layer of any desired metallic spray material can be produced on this first metallic layer will.
  • the heat of the molten spray particles from the second spray material striking the substrate is absorbed and homogenized by the first metallic layer, thereby avoiding thermal damage to the actual substrate material.
  • This procedure also makes it possible to build up multi-layer systems as described above.
  • the first electrically conductive component and / or the second electrically conductive component (a) multilayer system (s) which is / are thermally sprayed is / are arranged on the heating layer and a first metallic layer made of a spray material which has a melting temperature which is a maximum of 300 ° C. above the thermal load of the substrate element, and a layer made of a further spray material selected from one of copper, brass and aluminum.
  • the structure of the heating device described here in particular with superimposed functional layers in the form of contacting layers and a heating layer, different design variants are possible, for example a flexible film-based heating system, a direct structure of the heating system on non-electrically conductive structures with complex three-dimensional geometries, or a direct structure of the heating system on electrically conductive structures with complex three-dimensional geometries.
  • the present invention relates in particular to the combination of thermally sprayed contacts and a heatable coating.
  • One embodiment of the invention relates to the current flow perpendicular to the plane of the layer.
  • the substrate element can preferably be designed as a three-dimensional structure. Any three-dimensional structures, including complex three-dimensional structures, can thus be heated.
  • the heating device described herein can be built up on a substrate element in the form of a film-like carrier material.
  • the advantage of this design is that a flexible heating system can be generated in this way, which can be individually adapted to the respective application.
  • polymer films are primarily used as substrate films Consideration.
  • a metallic foil as the carrier material. In this case, there is no need to build up a first contact-making layer, since the electrically conductive substrate itself can function as a full-area contact.
  • the advantage over conventional heating foils is that the heating system can be produced in any surface of any shape and the heating system according to the invention can also be produced in this embodiment as rolled goods, which can be produced by cutting into the desired shape can be brought. Due to the flexibility of the heating system, two-dimensionally curved structures can be heated.
  • the heating device described herein is built up directly on a solid, non-conductive support structure, for example a plastic component.
  • a solid, non-conductive support structure for example a plastic component.
  • the first electrically conductive component of the heating device can be designed as a substrate element of the component.
  • This exemplary embodiment results, for example, from the use of electrically conductive structures or components as supports for the heating device described herein. This results in the possibility of using the carrier structure itself for introducing current, in particular for making contact, into the heating layer. This significantly reduces the manufacturing effort, since only one contact layer has to be produced.
  • the direct contact of the heating system with the component to be heated enables optimal heat transfer, which prevents heat losses and increases the overall energy efficiency of the heating.
  • the method is preferably designed to produce a component according to the invention as described above, so that reference is made and referenced in full to the corresponding statements above.
  • the first electrically conductive component can preferably be applied to a substrate element, in particular by means of an application process, preferably by means of a thermal spray process, such as an arc spray process, in particular an arc spray process, as described above for the heating devices described herein.
  • a contacting layer for example a metal layer, is applied to any carrier substrate that is a temperature-sensitive and / or foamed thermoplastic polymer.
  • the substrate element itself, to which the heating device is applied and which is a temperature-sensitive and / or foamed thermoplastic polymer can be designed as an electrically conductive component.
  • the heating layer here a layer that can be heated by an electric current, can preferably be applied to the first electrically conductive component by means of an application method, in particular by means of a spray method, a roll method or a doctor blade method.
  • the second electrically conductive component can be applied to the heating layer by means of an application process, in particular by means of a thermal spray process, for example an arc spray process, in particular an arc spray process, as described above for the heating devices described herein.
  • high-temperature electrical contacts can be applied at room temperature.
  • Many other electrical contacts are not suitable for high temperatures (e.g. 500 ° C) because they are glued on, for example, and the adhesive used does not have sufficient temperature resistance.
  • Other solutions for example inorganic-based conductive varnishes, have to be sintered at high temperatures in order to achieve their properties.
  • the thermally sprayed contacts are stable up to very high temperatures, but can be applied at room temperature. The process is of particular interest for high-temperature applications when contacts can no longer be glued on or when conductive pastes cannot be burned in at 600-900 ° C. In the present case, high-temperature contacts can be applied at room temperature, which is a considerable advantage. Good adhesion exists over the entire temperature range.
  • the figures show a component 10 according to the invention which has a substrate element 11.
  • the component also has an electrical heating device 20.
  • the electrical heating device 20 has a first conductive component 21 in the form of a contacting layer, a heating layer 22, and a second conductive component 23 in the form of a contacting layer.
  • the heater 20 described herein is built up through a sequence of coating operations.
  • the functionality is achieved through the combination of at least one heating layer 22 based on polymers doped with carbon nanoparticles and contacting this heating layer 22 with at least one second conductive component 23 applied over the entire area in the form of a metal layer.
  • arc spraying which belongs to the group of thermal spraying processes, is used to produce this metallic contact-making layer.
  • a first electrically conductive component 21, for example a metallic contacting layer is applied to any substrate element 11, for example a carrier substrate, by means of arc spraying.
  • a coating that can be heated by an electric current, the heating layer 22 is applied to the conductive component 21 produced.
  • This heating layer 22 can be applied by various application methods, such as spraying, rolling or knife coating, for example.
  • a second conductive component 23, for example a metallic contact-making layer 23 is applied to the heating layer 22.
  • the procedural steps are in Figure 1 shown.
  • the contacting layers produced serve as area-wide contacting of the heating layer 22.
  • the sandwich-shaped heating produced in this way in which a current flow is ensured across the component surface, is characterized in that it can be generated on any surface geometry and topology, including three-dimensional structures. This makes it possible to homogeneously heat even complex-shaped components and structures, as exemplified in Figure 2 is shown.
  • the heating device described herein is built up on a film-like substrate element 11 as a carrier material.
  • the advantage of this design is that a flexible heating system can be generated in this way, which can be individually adapted to the respective application.
  • polymer films are particularly suitable as substrate films.
  • a metallic foil as the carrier material.
  • the first method step that is to say the construction of the first electrically conductive component, is omitted, since the electrically conductive substrate itself can function as a full-surface contact.
  • the first conductive component 21, the heating layer 22 and the second conductive component 23 are then applied one after the other to the substrate element 11.
  • the advantage over conventional heating foils is that the component 10, as a heating system, can be produced in any surface of any shape; on the other hand, the heating system according to the invention in this embodiment can also be produced as rolled goods, which can be brought into the desired shape by cutting. Because of the flexibility of the heating system, two-dimensionally curved structures can thus be heated.
  • the heating device 20 described herein is built up directly on a solid, non-conductive support structure which represents the substrate element 11, for example a plastic component.
  • the structure is analogous to the exemplary embodiment in Figure 3 So a total of 3 layers are produced on the substrate element 11 as a carrier structure.
  • the component 10 which can be a heating system, can be produced directly on complex, three-dimensionally shaped structures or components. This enables a very high degree of adaptability to a wide variety of applications and represents a considerable advantage over all heating systems available on the market.
  • FIG. 5 Another embodiment shown in Figure 5 is shown, results from the use of electrically conductive structures or components as substrate element 11 for the heating device 20 described herein. This results in the possibility of using the substrate element 11 itself as an electrically conductive component 21 for introducing current or contacting the heating layer 22. This significantly reduces the production effort, since only one electrically conductive component 23 has to be produced.
  • the electrically conductive components for example the metallic
  • Contacting layers are produced as a type of pattern, for example in a meandering manner.
  • Various embodiments are shown in Figure 6 shown. This increases the flexibility of the heating device described herein. Furthermore, any differences in the thermal expansion coefficients can be compensated for by this contacting and the resulting mechanical stresses between the functional layers can be reduced or avoided.
  • Another advantage that results from this embodiment is that the arrangement of the contact surfaces can influence the flow of heating current in such a way that different temperature ranges or heating zones can be implemented in the surface to be heated.
  • the heating layer 22 is contacted by spraying on electrically conductive components 21, 23 in the form of contacting surfaces by means of arc spraying only on the sides of the surface to be heated in the form of a substrate element 11.
  • a corresponding example is given in Figure 7 shown.
  • the metallic contact-making layers in a graded manner. This means that through a targeted selection of the process parameters during thermal spraying of the contact layers, the properties, for example pore size, number of pores, of the resulting metallic layer can be set in such a way that mechanical stresses can be compensated.
  • Another possibility to specifically reduce mechanical tensions between the functional layers and thus to increase the service life of the heating system is to build up the metallic contact layers as a multi-layer system made of different materials.
  • suitable Materials By choosing suitable Materials, both good electrical contact and targeted voltage reduction can be guaranteed.
  • One example is a system made from the materials copper, tin and zinc. An example of this is in Figure 8 shown.
  • a comb structure is shown.
  • the current flows between the bars.
  • Such a configuration is suitable, for example, for large areas, floors, walls, mold construction, machine / tool construction.
  • the heating layer can also be drawn beyond the web ends to the corresponding conductive component, which is, for example, a counter electrode, so that the area between the electrically conductive components, which are electrodes, for example, is completely coated.
  • Figure 10 shows a simple variant with two parallel contacts. Such a configuration is suitable for small to medium-sized areas, automobiles, aerospace, mold construction, machine / tool construction.
  • Figure 11 shows a variant with ring-shaped contacts.
  • the current flows between the two ring electrodes.
  • This configuration is suitable, for example, for vessels, machine / tool construction. However, it does not have to be a ring. A full circle can also be used.
  • Figure 12 shows a variant with rigid or flexible arched / archable surfaces, such as sheets, foils, textiles and the like. This configuration is suitable, for example, for applications in connection with the Figures 9 to 13 are described. If you think further about this exemplary embodiment, you can also imagine, for example, a tube contacted at both ends or lengthways, for example by rolling it up.
  • FIG 13 a variant with "floating" contacts for potential distribution on more complex surfaces is shown. Such a configuration can be used, for example, for floors in vehicles, for example rail vehicles, shipping, and the like. At the in Figure 13 The illustrated embodiment can also be applied to the floating contacts.
  • a requirement with a uniform thickness of the heating layer is that the contacts are parallel. These don't have to be straight. Contacts can be placed under or over the heating layer. Any other geometric arrangement of the contacts requires a local adjustment of the layer thickness of the heating layer, but this is entirely possible with modern printing processes.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Resistance Heating (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Surface Heating Bodies (AREA)
EP13719273.8A 2012-04-20 2013-04-19 Elektrische heizvorrichtung, bauelement sowie verfahren zu deren herstellung Active EP2839717B1 (de)

Applications Claiming Priority (2)

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PCT/EP2013/001172 WO2013156162A2 (de) 2012-04-20 2013-04-19 Elektrische heizvorrichtung, bauelement sowie verfahren zu deren herstellung

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US10440829B2 (en) 2014-07-03 2019-10-08 United Technologies Corporation Heating circuit assembly and method of manufacture
DE102015214628A1 (de) * 2015-07-31 2017-02-02 BSH Hausgeräte GmbH Heizeinrichtung für ein Haushaltsgerät
EP3165761B1 (de) * 2015-11-03 2019-05-22 Nordex Energy GmbH Windenergieanlagenrotorblatt mit einer elektrischen heizeinrichtung
CN105578629B (zh) * 2016-02-29 2019-03-26 比赫电气（太仓）有限公司 一种金属柔性发热膜及其制备方法
PL3443810T3 (pl) * 2016-04-15 2022-08-16 Levidian Nanosystems Limited Elementy grzejne, wymienniki ciepła oraz układy elementów grzejnych
US10392810B1 (en) * 2016-06-22 2019-08-27 James Demirkan Universal lightweight and portable deicing mat
DE102016214489A1 (de) * 2016-08-04 2018-02-08 Continental Automotive Gmbh Metallische Folie mit aufgebrachtem flächigem elektrischem Leiter und unter Verwendung der Folie hergestellter Wabenkörper
US10264627B2 (en) * 2016-12-08 2019-04-16 Goodrich Corporation Adjusting CNT resistance using perforated CNT sheets
DE202016107401U1 (de) 2016-12-27 2017-02-01 Christian Furtmayr Heizsystem und Kit zum Herstellen eines Heizsystems
DE102016125742A1 (de) 2016-12-27 2018-06-28 Christian Furtmayr Heizsystem, Kit zum Herstellen eines Heizsystems und Verfahren zur deren Verwendung
DE102018203430A1 (de) 2018-03-07 2019-09-12 Voestalpine Stahl Gmbh Flächenelektrobauteil und verfahren zur herstellung
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US20150189699A1 (en) 2015-07-02
CN104584681B (zh) 2018-09-25
WO2013156162A3 (de) 2013-12-05
CN104584681A (zh) 2015-04-29
JP6185983B2 (ja) 2017-08-23
JP2015515104A (ja) 2015-05-21
HK1207239A1 (zh) 2016-01-22
EP2839717A2 (de) 2015-02-25
US10231287B2 (en) 2019-03-12

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