WO2010040139A1 - Compositions de revêtement chauffées et procédés d’utilisation - Google Patents
Compositions de revêtement chauffées et procédés d’utilisation Download PDFInfo
- Publication number
- WO2010040139A1 WO2010040139A1 PCT/US2009/059587 US2009059587W WO2010040139A1 WO 2010040139 A1 WO2010040139 A1 WO 2010040139A1 US 2009059587 W US2009059587 W US 2009059587W WO 2010040139 A1 WO2010040139 A1 WO 2010040139A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- graphite
- coating
- conductive
- composition
- electrically
- Prior art date
Links
- 239000008199 coating composition Substances 0.000 title claims description 15
- 238000000034 method Methods 0.000 title claims description 10
- 238000000576 coating method Methods 0.000 claims abstract description 85
- 239000011248 coating agent Substances 0.000 claims abstract description 57
- 239000004020 conductor Substances 0.000 claims abstract description 24
- 229920005989 resin Polymers 0.000 claims abstract description 22
- 239000011347 resin Substances 0.000 claims abstract description 22
- 239000000758 substrate Substances 0.000 claims abstract description 18
- 239000004593 Epoxy Substances 0.000 claims abstract description 13
- KPUWHANPEXNPJT-UHFFFAOYSA-N disiloxane Chemical class [SiH3]O[SiH3] KPUWHANPEXNPJT-UHFFFAOYSA-N 0.000 claims abstract description 8
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 88
- 239000010439 graphite Substances 0.000 claims description 80
- 229910002804 graphite Inorganic materials 0.000 claims description 80
- 239000000203 mixture Substances 0.000 claims description 47
- 239000002245 particle Substances 0.000 claims description 23
- 230000005611 electricity Effects 0.000 claims description 9
- 230000015556 catabolic process Effects 0.000 claims description 3
- 239000012799 electrically-conductive coating Substances 0.000 claims description 2
- 230000008878 coupling Effects 0.000 claims 1
- 238000010168 coupling process Methods 0.000 claims 1
- 238000005859 coupling reaction Methods 0.000 claims 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 21
- 229910052802 copper Inorganic materials 0.000 description 19
- 239000010949 copper Substances 0.000 description 19
- 239000000463 material Substances 0.000 description 15
- -1 polypropylene Polymers 0.000 description 11
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 8
- 229910052799 carbon Inorganic materials 0.000 description 8
- 238000010438 heat treatment Methods 0.000 description 8
- 229920001296 polysiloxane Polymers 0.000 description 7
- CTQNGGLPUBDAKN-UHFFFAOYSA-N O-Xylene Chemical compound CC1=CC=CC=C1C CTQNGGLPUBDAKN-UHFFFAOYSA-N 0.000 description 6
- 239000006229 carbon black Substances 0.000 description 6
- 239000012749 thinning agent Substances 0.000 description 6
- 239000008096 xylene Substances 0.000 description 6
- 239000003795 chemical substances by application Substances 0.000 description 5
- 229920001940 conductive polymer Polymers 0.000 description 5
- 239000011159 matrix material Substances 0.000 description 5
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 239000000654 additive Substances 0.000 description 4
- 239000000470 constituent Substances 0.000 description 4
- 239000012530 fluid Substances 0.000 description 4
- 229910052759 nickel Inorganic materials 0.000 description 4
- 239000003973 paint Substances 0.000 description 4
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 4
- 239000000843 powder Substances 0.000 description 4
- 229910052782 aluminium Inorganic materials 0.000 description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 3
- 238000005260 corrosion Methods 0.000 description 3
- 230000007797 corrosion Effects 0.000 description 3
- 238000012423 maintenance Methods 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 239000000047 product Substances 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 2
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- QXJJQWWVWRCVQT-UHFFFAOYSA-K calcium;sodium;phosphate Chemical compound [Na+].[Ca+2].[O-]P([O-])([O-])=O QXJJQWWVWRCVQT-UHFFFAOYSA-K 0.000 description 2
- 239000000919 ceramic Substances 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 238000010411 cooking Methods 0.000 description 2
- 238000006731 degradation reaction Methods 0.000 description 2
- 239000003085 diluting agent Substances 0.000 description 2
- 239000006185 dispersion Substances 0.000 description 2
- 238000009408 flooring Methods 0.000 description 2
- 239000011521 glass Substances 0.000 description 2
- NUJOXMJBOLGQSY-UHFFFAOYSA-N manganese dioxide Chemical compound O=[Mn]=O NUJOXMJBOLGQSY-UHFFFAOYSA-N 0.000 description 2
- 229910044991 metal oxide Inorganic materials 0.000 description 2
- 150000004706 metal oxides Chemical class 0.000 description 2
- 239000002923 metal particle Substances 0.000 description 2
- 239000013528 metallic particle Substances 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 239000000049 pigment Substances 0.000 description 2
- 229910052697 platinum Inorganic materials 0.000 description 2
- 229910052709 silver Inorganic materials 0.000 description 2
- 239000004332 silver Substances 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 2
- 229920002554 vinyl polymer Polymers 0.000 description 2
- 239000002023 wood Substances 0.000 description 2
- 229910001369 Brass Inorganic materials 0.000 description 1
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- 229910000881 Cu alloy Inorganic materials 0.000 description 1
- 208000030984 MIRAGE syndrome Diseases 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 241000872198 Serjania polyphylla Species 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 238000007605 air drying Methods 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 239000002518 antifoaming agent Substances 0.000 description 1
- 239000010426 asphalt Substances 0.000 description 1
- 239000010951 brass Substances 0.000 description 1
- 230000001680 brushing effect Effects 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 239000004568 cement Substances 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000003638 chemical reducing agent Substances 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 238000004040 coloring Methods 0.000 description 1
- 239000011231 conductive filler Substances 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 239000002274 desiccant Substances 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 239000002283 diesel fuel Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 239000000806 elastomer Substances 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 239000007770 graphite material Substances 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 235000000396 iron Nutrition 0.000 description 1
- 230000000670 limiting effect Effects 0.000 description 1
- 230000005923 long-lasting effect Effects 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 150000001247 metal acetylides Chemical class 0.000 description 1
- 229910001092 metal group alloy Inorganic materials 0.000 description 1
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 1
- 239000011859 microparticle Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 239000000178 monomer Substances 0.000 description 1
- 150000004767 nitrides Chemical class 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 238000010422 painting Methods 0.000 description 1
- 150000002978 peroxides Chemical class 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 229910052573 porcelain Inorganic materials 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- TVLSRXXIMLFWEO-UHFFFAOYSA-N prochloraz Chemical compound C1=CN=CN1C(=O)N(CCC)CCOC1=C(Cl)C=C(Cl)C=C1Cl TVLSRXXIMLFWEO-UHFFFAOYSA-N 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 230000002829 reductive effect Effects 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 230000004044 response Effects 0.000 description 1
- 230000002441 reversible effect Effects 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 229910052715 tantalum Inorganic materials 0.000 description 1
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 229910052718 tin Inorganic materials 0.000 description 1
- 239000011135 tin Substances 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 230000001052 transient effect Effects 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- 239000010937 tungsten Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 239000000080 wetting agent Substances 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- 239000011787 zinc oxide Substances 0.000 description 1
Classifications
-
- 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
- H05B3/16—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor the conductor being mounted on an insulating base
-
- 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
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M4/64—Carriers or collectors
- H01M4/66—Selection of materials
- H01M4/668—Composites of electroconductive material and synthetic resins
-
- 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/10—Energy storage using batteries
Definitions
- the present invention relates to compositions that are applied as a coating to a substrate to both protect it and to produce a heated and heat-radiating surface, and more particularly to coatings that use conductive particles for achieving remarkable heating characteristics. These particles could be non-metallic or metallic or combinations thereof.
- Nishino U.S. Pat. No. 4,714,569 proposes reacting a mixture of graphite and carbon black with a vinyl monomer in the presence of a peroxide to graft the vinyl based polymer onto the surface of the graphite and carbon black to produce a conductive polymer matrix.
- Nahass U.S. Pat. No. 5,591,382 discloses paints for charge dissipation where the paints include cylindrical graphite carbon fibrils and a conductive polymer matrix.
- Mahabandi U.S. Pat. No. 5,575,954 proposes conventional metallic and carbon conductive fillers in a unique binder to produce a conductive polymer matrix.
- Wakita (U.S. Pat. No. 5,567,357) proposes silver-plated copper powder to make a conductive polymer matrix.
- Kim (U.S. Pat. No. 5,556,576) proposes the use of metal, metal- coated glass, ceramics or conductive carbon to prepare a conductive polymer matrix.
- Namura (U.S. Pat. No. 5,549,849) proposes a combination of graphite particles, metal particles and carbon black to prepare conductive coatings.
- Hari U.S. Pat. No. 5,516,546 proposes amorphous or spherical graphite, carbon fiber, metal particles or mixtures thereof, to prepare conductive coatings.
- Wakabayashi U.S. Pat. No. 5,425,969 proposes a conductive primer for polypropylene that utilizes carbon black, graphite, silver, nickel or copper.
- Ota (U.S. Pat. No. 5,407,741) proposes to use spherical graphic particles having a diameter of less than 500 Fm to prepare an exothermic conductive coating.
- Ota (U.S. Pat. No. 5,378,533) proposes metallic coated hollow glass spheres for preparation of a conductive coating.
- Li (U.S. Pat. No. 5,372,749) proposes a surface treatment for conductive copper powder.
- Rowlette proposes to use a mixture of conductive metal oxide powder and non-conductive particles to prepare an anisotropically, electrically-conductive coating composition.
- Shrier proposes to use metals, metal alloys, conductive carbides, conductive nitrides, conductive borides and metal-coated glass spheres to prepare a nonlinear transient over-voltage protection coating.
- Yokoyama U.S. Pat. No. 5,242,511 proposes a copper alloy powder for use in electromagnetic shielding and similar uses.
- Mio U.S. Pat. No. 4,857,384 proposes to use metal oxide powder in preparing an exothermic conducting paste.
- Gindrup U.S. Pat. No. 4,624,798 proposes to use metal-coated microparticles in preparing electrically-conducting compositions.
- Ellis proposes a blend of graphite, manganese dioxide and zinc oxide in preparing electrically conductive compositions.
- Neumann proposes to use metallic carbide in preparing paints that have low electrical impedance orthogonal to the plane of the coating.
- the present invention in its various embodiments solves many of the problems encountered in the art by providing conductive coatings that can generate heat when an electrical current is applied to the coating; where the coating can be applied to many different surface types; and the coating is not degraded by the heat produced in response to the electrical current.
- the present invention is compositions that may be used as coatings to produce safe and efficient heat when an electrical charge is applied to the coating.
- the compositions of the present invention have unique adhesion, durability, flexibility and corrosion-resistant characteristics which allow them to adhere to a wide range of selectable substrate materials.
- the invention is also directed to uses of the coatings to provide heating to a variety of surfaces, and for a multitude of purposes.
- the coatings of the present invention comprise a base constituent.
- the base is a siloxane- based resin or resins.
- Siloxane -based resins are known to have improved properties of flexibility, weatherability, compressive strength and chemical resistance.
- it has been discovered in the present invention that such bases are unexpectedly well-suited for use in the context of heated coatings.
- epoxy polysiloxane hybrids are able to withstand extreme temperatures — which allows the present composition to remain stable when generating temperatures up to 2000° F, and higher. It was also discovered that such bases do not readily degrade when electrical current is run through them. .
- the coating compositions of the present invention may further include additives that modify or enhance the characteristics of the base constituent siloxane-based resin, such as, for example, to improve hardness, adherence, flexibility, corrosion resistance, durability and/or finish.
- a thinning agent may also be added to improve pouring or other application characteristics.
- One particularly suitable thinning agent that may be used is xylene or a xylene- based thinner.
- compositions of the present invention further include a conductive material.
- the conductive material can be non-metallic, metallic, semi-metallic or combinations thereof.
- the conductive material in one embodiment is graphite particles.
- the graphite particles may be prepared using conventional manufacturing equipment and techniques.
- the graphite or other conductive material is dispersed in the base constituent material such that the resulting coating produces heat when either low or high voltage AC or DC current is passed through it.
- Other forms of carbon may also be used, such as carbon black.
- the graphite may be synthetic or natural, and may be crystalline, spherical, flake, amorphous, or combinations thereof. In one embodiment, the graphite is not coated with nickel or copper, a "non-metallic graphite.”
- the composition can then be applied to a substrate as a coating.
- a current Upon application of a current, the coating generates heat.
- the electrical current can be AC or DC and does not need to be tuned or of a specific form.
- the system can accept what is known as a dirty wave.
- the coating may be charged or energized with less than 300 watts over a 50 square foot area, which, in one embodiment, will produce heat over 100° F on its surface.
- the resistance of the coating may be selected to produce a desired result and the coating is capable of producing a non-runaway heat using both AC and DC currents.
- the coatings of the invention in its various embodiments will adhere to a wide variety of substrates, including, but not limited to, glass, porcelain, concrete, metals, woods, plastics and asphalt.
- a heat-emitting surface is produced by applying to a selected surface an electrical conductor or conductor system, such as copper stripping, for example, that is applied in a buss or grid system, or in any other suitable form that is best suited to the area and surface being coated.
- the surface, with electrical conductor applied thereto is coated with the composition of the present invention.
- the coating composition is typically applied in a thickness of between about Vi mil and about 12 mils. In one embodiment, the coating is applied in a thickness of about 6 mils. However, in other embodiments, it may be desirable to apply the coating even thinner than Vi mil and thicker than 12 mils depending on the application, and this range is not intended to be an upper and lower limit of the present invention, but rather an illustrative application.
- Additional layers of the coating composition may be applied as desired or required by the particular application.
- additional layers of other materials may be applied over the coating composition.
- Such other materials may include, but are not limited to, thin layers of pigmented coatings to impart a desired color or coloring effect, or texture, and coatings that impart a certain finish, such as gloss or matte finish.
- heat-emitting coated surface may be controlled with a regulating system and may be zoned to provide a different desired temperature in each zone.
- the coatings may be used in combination with other heating systems or mechanisms.
- heating zones may be cycled on and off at any desired interval and between an unlimited amount of stations.
- the coatings of the invention may be essentially "solid state" and do not require maintenance over the regular service life of the coated surface. Furthermore, the coatings may be serviced by merely touching up the coating, e.g. repainting or recoating a damaged area.
- Advantages of the present invention in its various embodiments include, but are not limited to, its ability to generate and/or withstand temperatures ranging up to around 2000° F; its ease of application and maintenance (it can be thinned to desired consistency and applied by brush, roller coat, reverse roller coat, spray and other techniques known in the art); its resistance to current-induced degradation; and its wide applicability.
- FIG. 1 shows a view in cross section of a coated surface in accordance with one embodiment of the present invention.
- FIG. 2 shows a plan view of a means for producing a heat emitting coated surface according to one embodiment of the present invention.
- FIG. 3 shows a grid system for application of the heat emitting coated surface.
- the coating compositions of the invention are durable and long lasting and can help protect the surfaces to which they are applied. They are also able to generate and emit heat that is useful in a wide variety of applications.
- the coatings may be used in architectural or building structures to heat, for example, floors, walls, ceilings, roofs and gutters.
- the coatings may be applied to and used for preheating of engine fluids, such as oil, in a vehicle or other mechanical device, applying heat to a tank carrying fluid susceptible to low temperatures, such as diesel fuel, and for deicing or preventing icing of aircraft.
- the coatings may also be used for heating road surfaces such as, for example, highways, roads, driveways, parking lots and bridges.
- coatings of the present invention include, but are not limited to, domestic and industrial equipment or machinery such as, for example, dryers, irons, clothes presses, space heaters, cooking surfaces, hot plates, electrical cooking appliances, toasters, coffee makers, water heaters, furnaces and medical equipment.
- the invention in its various embodiments contemplates a coating composition.
- the coating includes a base material, a conductive material and other optional additives.
- the base is an epoxy polysiloxane hybrid resin.
- Suitable epoxy polysiloxane hybrids for use in preparing the coatings of the present invention include but are not limited to the following, either alone or in combination: XylexinTM ESX-40, ESX-50, ESX-60, ESX-60Plain, UV 320, UV 340, UV 350, and UV 370 sold by Mirage Products of Orem, Utah; and 10 PSX, PSX-700, PSX-700A, PSX-892HS, PSX-1001 available from Ameron International, of Pasadena, California.
- Other suitable base materials include, but are not limited to, the coatings disclosed in U.S Patents 5,275,645 and 5,618,860 alone or in combination.
- At least one epoxy polysiloxane hybrid resin is used in the base material, but the compositions of the present invention may include one or more additional resins. These additional resins can improve the characteristics of the coating composition in terms of durability, flexibility, adhesion, color and/or gloss retention and corrosion resistance.
- One resin that may be used is solvent- free silicon epoxide resin.
- the coating compositions also may include thinning agents, such as xylene or xylene-based products, that can improve the application characteristics of the composition. The amount of thinning agent depends on the application, but generally falls between 1% and 50% by weight.
- the conductive material is graphite.
- graphite may be synthetic or natural, and may be crystalline, spherical, flake, amorphous, or combinations thereof.
- the graphite is not coated with nickel or copper — i.e. it is a "non-metallic graphite.”
- Other conductive materials that are not carbon based could also be utilized with the present invention in its various embodiments. These conductive materials include, but are not limited to copper, aluminum, silver, gold, iron and nickel, aluminum, chromium, manganese, platinum, tantalum, titanium, tin, tungsten, and zinc.
- the conductive material preferably ranges in particle size from a mesh of about -325 (44 microns) up to a mesh size of about +325.
- mesh size smaller than about -325 typically results in such a fine powder that is hard to handle; and mesh size larger than about +325 tends to reduce the conductivity of the coating below desirable levels. That notwithstanding, these are not intended to be limits on the scope of the present invention.
- particles smaller than -325 mesh size or larger than +325 mesh size may be desirable and are considered to be within the scope of the present invention in its various embodiments.
- the conductive material can be a mixture of mesh sizes — which it has been discovered improves conductivity.
- the concentration of conductive material is between 1 and 75% by weight of the composition. Concentrations of conductive material lower than 1% tend to not exhibit the requisite conductivity for most applications. Concentrations of conductive material higher than 75% tend to decrease the resistance to a point where they are likewise not suitable for most applications. That notwithstanding, these ranges are not intended to be limits on the scope of the present invention. In some situations concentrations of less than 1% by weight or more than 75% by weight may be desirable and are considered to be within the scope of the present invention in its various embodiments.
- the composition contains a combination, in equal measure, of three graphite mixtures denoted as follows:
- Asbury Graphite #4012 available from Asbury Carbons of Asbury, New Jersey, which comprises:
- Asbury Graphite #23 OU also available from Asbury Carbons of Asbury, New Jersey, which comprises:
- a coating composition according to one embodiment of the present invention, is made as follows:
- thinning agent e.g. xylene or xylene based materials
- the mixture is made by adding the graphite material to the epoxy polysiloxane hybrid resin and mixing until the graphite particles are evenly distributed and fully suspended. Then the thinning agent is added and the mixture is stirred until the graphite particles are well-mixed and suspended.
- composition of the invention can be applied to a substrate by any method known in the painting arts, such as spraying, rolling, brushing or pouring.
- the coating is typically applied to the substrate in thickness of between about 1 A mil to about 12 mils. In one embodiment, about a 6 mil layer is applied.
- the coating may be cured by air-drying. Heat or bake curing and other methods of curing known in the art may also be used. Bake curing is preferred in those embodiments where high temperatures (i.e. those exceeding 375° F) are to be generated by the coating.
- the resulting coating provides an extremely heat-resistant, weather resistant, UV light resistant and electrical degradation-resistant coating that can be used to produce heat emission from many surfaces.
- the resins of the invention have the ability to withstand significantly elevated temperatures without a loss of integrity. Therefore, the coatings of the invention in its various embodiments provide a stable product that may be applied to a number of surfaces, including bridges, airplanes and other structures subject to icing and harsh weather.
- the compositions of the invention are substantially free of any pigments.
- pigments can be added.
- the surface coated with the exothermic compositions may also be colored or provided with a desired texture by the addition of a separate coating that provides color, texture and/or a desired finish, such as flat, matte, gloss, etc.
- additives or agents may be incorporated into the coatings of the invention, including, but not limited to, accelerators, flow leveling agents, catalysts, drying agents, surfactants, diluents, solvents, thinners, antifoam agents, anti-scratch agents, flow control agents, wetting agents, and a wide variety of other conventional additives.
- diluents, solvents and/or thinners include, but are not limited to, EXS5, EXS7, EXS9, and thinners available from PPG Amercoat located in Pittsburgh, Pennsylvania.
- the coating and thinner provide a coating having a sufficiently long cure time such that the graphite and solids stack well during the curing process.
- FIG. 1 a cross section of a heat-emitting structure 10 according to one embodiment of the present invention is shown. An electrically conductive element 14 is applied to a substrate 12.
- the substrate 12 could be any number of surfaces on which it would be desirable to generate and emit heat including, but not limited to, cement, ceramic, wood, certain thermoset plastics, certain heat-resistant elastomers, etc.
- the substrate 12 can be part of any number of previously enumerated architectural, building, road, equipment or machinery surfaces.
- the electrically conductive element 14 is copper stripping but could be numerous other materials that would be apparent to one skilled in the art including, but not limited to, aluminum, brass and platinum.
- a layer 16 of the coating material as described in Example 1 below is then applied to the substrate 12 over the top of the electrically conductive element 14.
- a source of electricity 18 can then be attached to the electrically-conductive elements 14.
- the configuration and construction of means for applying electricity to the electrically-conductive elements 14 is well within the skill in the art.
- FIG. 2 illustrates a buss type system where two electrically-conductive elements 14, such as copper strips, are placed on the substrate 12 for transporting electricity to the coating.
- the width, length and proximity of placement of the electrically-conductive elements 14 will depend on the particular application.
- the electrically-conductive elements 14 may be sized in width to be between 0.10 inches and 3.0 inches, and may be spaced apart from each other a distance from between about three inches to about six feet.
- the electrically- conductive elements 14 are generally positioned at the edge of the area to be coated.
- buss system i.e. the number, size and relative locations of the electrically conductive elements-that would be needed would depend on the amount of current a user wished to direct through the coating. The amount of current desired would depend on the concentration of conductive material and the temperatures sought to be generated. Constructing an appropriate buss system would be readily ascertainable to one skilled in the art without undue experimentation.
- FIG. 3 illustrates a grid system where the electrically-conductive elements 14 are positioned on a substrate 12 in a grid-type pattern, where the spacing apart of the electrically-conductive elements 14 is determined by the application.
- a grid system of electrical conductors as illustrated in FIG. 3, may be used in applications where a very thin coat is applied or the coating has a higher resistance.
- using a grid system for the purpose of applying a current effectively lowers the resistance of the coating by decreasing the distance between the two electrodes.
- the coating may be applied to a driveway or parking area to prevent snow buildup and eliminate the need to plow or shovel the area.
- concentration of graphite should be increased.
- the electrical load may be selected to achieve a desired resistance and exothermic requirements for the application.
- a coating composition was prepared by adding to one gallon of epoxy polysiloxane hybrid material 16.6 pounds of mixed graphite containing equal amounts of Asbury graphite #4012, Asbury graphite #23 OU and Asbury graphite #A625. The graphite and resin were mixed thoroughly and then one gallon of xylene-based thinner was added. The mixture was again stirred until the graphite particles were evenly distributed and fully suspended. The composition was then applied to a surface having electrical contacts previously installed.
- the electrical contacts in this example are strips of copper tape laid down on the target surface, with the distance between the strips being determined by the resistance of the material, represented in Ohm's, the input current, the resistance of the coating and voltage.
- Copper strips that are approximately 2mm thick may be applied to the back of a six inch square tile and the coating composition can then be then applied over the copper strips to a thickness of at least 1 mil (resistance being about 12.5 Ohms). Approximately 50 volts can be applied across the copper strips, which results in heat being generated in the coating and transmitted to the tile such that the tile acts as a radiant heat source. In this example, it would take about 50 volts to heat 25 square feet of flooring.
- XylexinTM EXS-50 Four ounces of XylexinTM EXS-50 are prepared according to the directions provided therewith, to which is added four fluid ounces of a -300 mesh graphite (99% pure).
- the graphite is then mixed into the ESX-50 and the coating can be applied to a surface having electrical contacts previously installed.
- the electrical contacts are strips of copper tape laid down on the target surface, with the distance between the strips determined by Ohm's law, the input current, the resistance of the coating and voltage. Copper strips that are approximately 2 mm thick may be applied to the back of a six inch square tile and the Xylexm/graphite coating then applied over the copper strips to a thickness of at least 2 mm (resistance being about 1.6 Ohms). Less than or equal to about 6 volts is applied across the copper strips, which results in heat being generated in the coating and transmitted to the tile such that the tile acts as a radiant heat source. In this example, it would take about 80 watts
- Two ounces of XylexinTM EXS-50 are prepared according to the directions provided therewith, to which is added six fluid ounces of a -300 mesh graphite (99% pure) and four ounces of XL reducer. The graphite is then mixed in to produce a coating. Copper tape is laid down in strips on the target surface, with the distance between the strips determined by Ohm's law, the input current, the resistance of the coating and voltage.
- Copper strips that are approximately 2 mm thick may be applied to the back of a six inch square tile and the Xylexin/graphite coating then applied o ⁇ er the copper strips to a thickness of at least 2 mm (resistance being about 1.6 Ohms). Less than or equal to about 6 volts is applied across the copper strips, which results in heat being generated in the coating and transmitted to the tile such that the tile acts as a radiant heat source. In this example, it would take about 80 watts to heat 400 square foot floor.
- Ten ounces of XylexinTM 50 XL are prepared according to the directions provided therewith, to which is added four ounces of 23Ou -325 graphite from Asbury; four ounces of a625 99.95 @ -100 mesh from Asbury; and six ounces of 3061 graphite.
- the graphite and resin are mixed thoroughly and then two ounces of 911 thinner available from PPG Pittsburgh Paint in Pittsburgh, Pennsylvania are added. The mixture is again stirred until the graphite particles are evenly distributed and fully suspended.
- the composition is then applied to a surface having electrical contacts previously installed and allowed to air dry.
- XylexinTM HC55 Twelve ounces of XylexinTM HC55 are prepared according to the directions provided therewith, to which is added eight ounces of 4012 synthetic, min 98% carbon, 99% -100 from Asbury; and eight ounces of a625 99.95 @ -100 mesh from Asbury.
- the graphite and resin are mixed thoroughly and then four ounces of r200 fast are added. The mixture is again stirred until the graphite particles are evenly distributed and fully suspended.
- the composition is then applied to a surface having electrical contacts previously installed and bake cured for 45 minutes at 400 0 F.
- Three ounces of XylexinTM HC55 are prepared according to the directions provided therewith, to which is added two ounces of 4012 synthetic, min 98% carbon, 99% -100 from Asbury; and three ounces of a625 99.95 @ -100 mesh from Asbury.
- the graphite and resin are mixed thoroughly and then one ounce of 911 thinner is added.
- the mixture is again stirred until the graphite particles are evenly distributed and fully suspended.
- the composition is then applied to a surface having electrical contacts previously installed and bake cured for 45 minutes at 400 0 F.
- Ten ounces of XylexinTM 50 XL are prepared according to the directions provided therewith, to which is added six ounces of 23Ou -325 graphite from Asbury; four ounces of a625 99.95 @ - 100 mesh from Asbury; and four ounces of 3061 graphite.
- the graphite and resin are mixed thoroughly and then two ounces of 911 thinner are added. The mixture is again stirred until the graphite particles are evenly distributed and fully suspended.
- the composition is then applied to a surface having electrical contacts previously installed and allowed to air dry.
- Ten ounces of XylexinTM 40 XL are prepared according to the directions provided therewith, to which is added three ounces of 23Ou -325 graphite from Asbury; six ounces of a625 99.95 @ - 100 mesh from Asbury; and six ounces of 3061 graphite.
- the graphite and resin are mixed thoroughly and then four ounces of 911 thinner are added. The mixture is again stirred until the graphite particles are evenly distributed and fully suspended.
- the composition is then applied to a surface having electrical contacts previously installed and allowed to air dry.
- Ten ounces of XylexinTM 50 XL are prepared according to the directions provided therewith, to which is added four ounces of 23Ou -325 graphite from Asbury; four ounces of a625 99.95 @ -100 mesh from Asbury; and six ounces of 3061 graphite.
- the graphite and resin are mixed thoroughly and then two ounces of 911 thinner are added. The mixture is again stirred until the graphite particles are evenly distributed and fully suspended.
- the composition is then applied to a surface having electrical contacts previously installed and allowed to air dry.
Landscapes
- Paints Or Removers (AREA)
Abstract
L’invention concerne un revêtement comprenant une base contenant une résine hybride époxy-siloxane, et un matériau électroconducteur, le revêtement pouvant communiquer avec un ou plusieurs éléments conducteurs sur divers supports afin de produire une surface émettant de la chaleur.
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US19517908P | 2008-10-03 | 2008-10-03 | |
US61/195,179 | 2008-10-03 |
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WO2010040139A1 true WO2010040139A1 (fr) | 2010-04-08 |
WO2010040139A4 WO2010040139A4 (fr) | 2010-05-20 |
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Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20120082806A1 (en) * | 2010-10-04 | 2012-04-05 | Kyle Ryan Kissell | Heatable coating with nanomaterials |
WO2020139639A1 (fr) * | 2018-12-26 | 2020-07-02 | Momentive Performance Materials Inc. | Compositions durcissables à base de silicone et leurs applications |
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US6479797B1 (en) * | 2000-06-05 | 2002-11-12 | Tigers Polymer Corporation | Snow melting apparatus and heating wire for melting snow |
US20030113606A1 (en) * | 2001-04-13 | 2003-06-19 | Rosalyn Ritts | Biocompatible membranes of block copolymers and fuel cells produced therewith |
US20080116424A1 (en) * | 2006-11-20 | 2008-05-22 | Sabic Innovative Plastics Ip Bv | Electrically conducting compositions |
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US6479797B1 (en) * | 2000-06-05 | 2002-11-12 | Tigers Polymer Corporation | Snow melting apparatus and heating wire for melting snow |
US20030113606A1 (en) * | 2001-04-13 | 2003-06-19 | Rosalyn Ritts | Biocompatible membranes of block copolymers and fuel cells produced therewith |
US20080116424A1 (en) * | 2006-11-20 | 2008-05-22 | Sabic Innovative Plastics Ip Bv | Electrically conducting compositions |
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Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20120082806A1 (en) * | 2010-10-04 | 2012-04-05 | Kyle Ryan Kissell | Heatable coating with nanomaterials |
WO2020139639A1 (fr) * | 2018-12-26 | 2020-07-02 | Momentive Performance Materials Inc. | Compositions durcissables à base de silicone et leurs applications |
US12116481B2 (en) | 2018-12-26 | 2024-10-15 | Momentive Performance Materials Inc. | Curable silicone-based compositions and applications thereof |
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WO2010040139A4 (fr) | 2010-05-20 |
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