WO2020221987A1 - Système de revêtement mural ou de sol chauffé - Google Patents

Système de revêtement mural ou de sol chauffé Download PDF

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Publication number
WO2020221987A1
WO2020221987A1 PCT/GB2020/050995 GB2020050995W WO2020221987A1 WO 2020221987 A1 WO2020221987 A1 WO 2020221987A1 GB 2020050995 W GB2020050995 W GB 2020050995W WO 2020221987 A1 WO2020221987 A1 WO 2020221987A1
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WO
WIPO (PCT)
Prior art keywords
electrically
conductive
coating composition
thermally
conductive coating
Prior art date
Application number
PCT/GB2020/050995
Other languages
English (en)
Inventor
Paul WOOLVINE
Ian Spreadborough
Sergey Alekseev
Marina STARKOVA
Original Assignee
!Obac Limited
Graphene Star Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by !Obac Limited, Graphene Star Ltd filed Critical !Obac Limited
Publication of WO2020221987A1 publication Critical patent/WO2020221987A1/fr

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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
    • H05B3/20—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
    • H05B3/26—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor mounted on insulating base
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/02—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
    • B05D3/0254—After-treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/50—Multilayers
    • B05D7/52—Two layers
    • B05D7/54—No clear coat specified
    • B05D7/544—No clear coat specified the first layer is let to dry at least partially before applying the second layer
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D133/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Coating compositions based on derivatives of such polymers
    • C09D133/04—Homopolymers or copolymers of esters
    • C09D133/06—Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, the oxygen atom being present only as part of the carboxyl radical
    • C09D133/08—Homopolymers or copolymers of acrylic acid esters
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D175/00—Coating compositions based on polyureas or polyurethanes; Coating compositions based on derivatives of such polymers
    • C09D175/02—Polyureas
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C09D5/24—Electrically-conducting paints
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/40—Additives
    • C09D7/60—Additives non-macromolecular
    • C09D7/61—Additives non-macromolecular inorganic
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/40—Additives
    • C09D7/66—Additives characterised by particle size
    • C09D7/69—Particle size larger than 1000 nm
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/40—Additives
    • C09D7/70—Additives characterised by shape, e.g. fibres, flakes or microspheres
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24D—DOMESTIC- OR SPACE-HEATING SYSTEMS, e.g. CENTRAL HEATING SYSTEMS; DOMESTIC HOT-WATER SUPPLY SYSTEMS; ELEMENTS OR COMPONENTS THEREFOR
    • F24D13/00—Electric heating systems
    • F24D13/02—Electric heating systems solely using resistance heating, e.g. underfloor heating
    • F24D13/022—Electric heating systems solely using resistance heating, e.g. underfloor heating resistances incorporated in construction elements
    • F24D13/024—Electric heating systems solely using resistance heating, e.g. underfloor heating resistances incorporated in construction elements in walls, floors, ceilings
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/02—Elements
    • C08K3/04—Carbon
    • C08K3/042—Graphene or derivatives, e.g. graphene oxides
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/02—Elements
    • C08K3/08—Metals
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/34—Silicon-containing compounds
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D125/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Coating compositions based on derivatives of such polymers
    • C09D125/02—Homopolymers or copolymers of hydrocarbons
    • C09D125/04—Homopolymers or copolymers of styrene
    • C09D125/08—Copolymers of styrene
    • C09D125/10—Copolymers of styrene with conjugated dienes
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D125/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Coating compositions based on derivatives of such polymers
    • C09D125/02—Homopolymers or copolymers of hydrocarbons
    • C09D125/04—Homopolymers or copolymers of styrene
    • C09D125/08—Copolymers of styrene
    • C09D125/14—Copolymers of styrene with unsaturated esters
    • 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
    • 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
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B30/00—Energy efficient heating, ventilation or air conditioning [HVAC]
    • 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
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00—Technologies relating to chemical industry
    • Y02P20/10—Process efficiency

Definitions

  • the present invention relates to providing liquid-applied, electrically-conductive coating compositions which are useful for the creation of electric underfloor or in wall heating systems with high energy efficiency.
  • Underfloor or in-wall heating is an increasingly popular technology for use in heating domestic and commercial properties. The technology is hidden, and is therefore more aesthetically pleasing than conventional radiators or free-standing heaters. Underfloor or in-wall heating distributes heat evenly around each corner of a room, is believed to be generally more efficient than traditional heating systems, and is considered to be a desirable addition to a home.
  • Underfloor and in-wall heating systems essentially fall into one of two categories - “dry” systems, which utilize electricity to heat the floor/wall; or“wet” systems, which utilize piped hot water to heat the floor/wall. Wet systems are more easily installed in cases where it is possible to take up an existing floor, or when new floors are being laid. Dry systems are more suitable for installation in existing rooms, as the systems are of a flatter profile and generally do not need floor heights to be adjusted.
  • Dry systems essentially comprise a network of electrical heating wires or cables beneath the floor, which can be in the form of loose-lay cables, pre-formed adhesive mats or carbon films.
  • mats are generally utilized to line the wall.
  • the conventional cable or mat systems provide radiant heat, whereas carbon film systems provide infrared heating.
  • Dry systems are generally much simpler to install than wet systems, and have lower associated installation costs.
  • the running costs of dry systems are significantly higher than their wet counterparts.
  • an electrically-conductive coating composition for use in providing an electrically- resistive heating element, the composition comprising:
  • composition therefore preferably forms an aqueous mixture.
  • water borne will be understood in the context of the present invention by the skilled addressee as meaning“conveyed by water”.
  • water-borne polymeric binder may therefore refer to a polymeric binder in admixture with water, or a polymeric binder in solution.
  • the present invention is directed toward providing liquid-applied, electrically- conductive coating compositions which are useful for creating electric underfloor heating systems or electric in-wall heating systems with high energy efficiency.
  • the composition also preferably provides for a moisture-breathable solution.
  • a porous structure is preferably formed.
  • the porous structure permits diffusion of vapour, which may include water vapour.
  • the composition therefore also preferably provides for a moisture- breathable solution, creating comfort in a heated room.
  • the electrically-conductive carbon allotrope is graphene.
  • the graphene consists of one or more selected from: graphene powder; graphene platelets.
  • the graphene is non-oxidised. Used in heated coatings graphene is preferably non-oxidized and comprises no defects, and it is thought that this feature aids in providing for the high electrical conductivity of graphene. It is thought that the presence of chemical compounds, oxides or defects on graphene plates leads to a sharp increase in resistance to electric current at the contact points of graphene plates.
  • the volume conductivity of non- oxidized graphene used in a heating coating such as that proposed is 50,000 S/m.
  • the volume conductivity of oxidized graphene is thought to be around 5,000 - 6,000 S/m.
  • Graphene is obtained by a low-temperature method from natural graphite, without the use of any chemical reagents. It is thought that graphene obtained by this method has a high electrical conductivity due to the absence of defects and deformations of graphene platelets. Without wishing to be bound by theory, graphene oxide (GO) has extremely low electrical conductivity, which is why it is generally called as electrical insulator. However, GO is oxidized from graphene which has a very high electrical conductivity (also called original or pristine graphene). GO conducts very low amounts of electrical current depending upon the level of its oxidation. A highly oxidized GO is an electrical insulator. To improve electrical conductivity, GO is generally reduced using several methods.
  • the reduced GO cannot generally conduct electricity to the level of pristine graphene, due to remaining defects in the reduced GO after reduction.
  • oxygen-containing groups are reduced and the carbon-containing groups are increased.
  • this particular feature preferably promotes electrical conduction (Hongtao Liu et al. , Reduction of graphene oxide to highly conductive graphene by Lawesson's reagent and its electrical applications., J. Mater. Chem. C, 2013, 1 , 3104-3109).
  • the graphene powder comprises graphene nanoplatelets each having a nanoplatelet thickness less than about 5 nm; and a nanoplatelet size less than about 50 microns.
  • the graphene nanoplatelets preferably have a nanoplatelet thickness less than 2 nm; and a nanoplatelet size in the range: 5 microns to 20 microns.
  • nanoplatelet size in the context of the present invention will be understood by the skilled addressee to be the distance along the longest dimension of the nanoplatelet.
  • Graphene powders and nanoplatelets have a tendency to clump together.
  • a water borne polymeric binder is preferably advantageous in providing for easier dispersion of graphene throughout the composition and therefore provide a more homogeneous mixture. It is thought that the homogeneous mixture provides better electrical and heat dispersion.
  • the graphene platelets preferably have an electrical conductivity greater than about 10 3 Siemens/metre (S/m).
  • the graphene platelets preferably have an electrical conductivity in the range: 10 3 S/m to 10 6 S/m.
  • An electrical conductivity selected from the range: 10 4 S/m to 10 5 S/m is particularly preferred.
  • Suitable graphene powders preferably include, for example, Graphene Nanoplatelets GS-030P and GS-030W, commercially available from Graphene Star Ltd.
  • the thermally-conductive powder is selected from the group consisting of: ferrosilicon, titanium dioxide, carbon microspheres and glass microspheres.
  • the composition comprises more than one of said thermally- conductive powders in combination.
  • the thermally-conductive powder comprises atomised ferrosilicon.
  • the term“atomised” will be understood by the skilled addressee to mean“converted to fine particles”, the relative size of said particles being inferable by the skilled addressee.
  • the ferrosilicon comprises a silicon content selected from the range: 10 % wt to 20 % wt; with a silicon content selected from between 14 % wt and 16 % wt being particularly preferred.
  • the atomised ferrosilicon preferably comprises ferrosilicon particles each having a particle size, the particle size being less than about 300 microns; with a particle size selected between 50 microns and 200 microns being particularly preferred.
  • particle size in the context of the present invention will be understood by the skilled addressee to refer to the average distance along the longest dimension of a particle.
  • Suitable ferrosilicon powders preferably include, for example, Atomised Ferrosilicon 15%, commercially available from M & M Alloys Ltd.
  • the thermally-conductive powder (TCP) is preferably combined with the electrically-conductive carbon allotrope (ECC) in a weight ratio of TCP : ECC.
  • the weight ratio is preferably selected from between 5:1 and 15: 1 ; with a weight ratio selected from between 8: 1 and 12: 1 being particularly preferred.
  • the TCP is ferrosilicon powder
  • the ECC is graphene.
  • the thermally- conductive powder and electrically-conductive carbon together constitute 50 to 90 weight percent of the aqueous mixture.
  • the thermally-conductive powder and electrically-conductive carbon together constitute 65 to 75 weight percent of the aqueous mixture.
  • a variety of water-borne polymeric binders are preferably suitable, with those based on polyurethane, acrylic, styrene- acrylic or styrene-butadiene polymers and co-polymers being preferred.
  • Suitable commercially available materials preferably include, for example, the following:
  • an electrically-conductive coating for use in an underfloor or in-wall heating system, the coating comprising a first electrically-conductive layer comprising an electrically-conductive carbon allotrope, a thermally-conductive powder, and a polymeric binder; and
  • the dielectric layer comprising a thermally-cured coating.
  • the first electrically-conductive layer is formed from an electrically- conductive composition according to the first aspect of the present invention described herein.
  • the thermally cured coating is a two-part coating which may comprise one or more resins selected from the group: epoxy; polyurethane; poly-urea.
  • thermosetting coatings are preferably suitable for use as the dielectric layer of the second aspect of the present invention.
  • suitable coatings include those based on epoxy, polyurethane or poly urea resins.
  • the coatings contain minimal volatile constituents, with 100% solids (solvent free) materials being particularly preferred.
  • poly-urea compositions comprising at least one aliphatic poly isocyanate component and at least one poly-aspartic acid ester component are preferred on account of their rapid curing characteristics.
  • an electrically-conductive heating system comprising:
  • the system further comprises a power supply in communication with the plurality of electrical contacts, the power supply being arranged to provide an electrical current to the contacts.
  • the electrical contacts are electrically-conducting strips.
  • the conductive strips comprise copper.
  • the conductive strips each comprise a conductive strip width selected from between 10 mm and 20 mm, and is most preferably 12.5 mm.
  • the conductive strips are preferably a maximum of about 1 m wide.
  • the conductive strip width of the plurality of conductive strips is the same.
  • flat conductive wires may be employed.
  • the flat conductive wires comprise copper.
  • the plurality of electrically-conductive contacts are at least partially embedded within the first electrically-conductive layer.
  • a method of forming an electrically-resistive heating element comprising the steps of:
  • the method may further comprise a step of connecting said network to a power supply.
  • the network of electrically- conductive strips or wires is adhered to the surface to be treated.
  • the network of electrically-conductive strips or wires are self-adhesive.
  • the network of electrically-conductive strips or wires comprise copper.
  • the electrically-conductive strips or wires are pure copper.
  • the electrically-conductive strips or wires in preferable embodiments may be superconductive.
  • the aqueous mixture is preferably applied in liquid form.
  • the water-borne binder aids in dispersing graphene platelets which may otherwise have a tendency to clump together with poor dispersion in less-aqueous mixtures.
  • the aqueous mixture is applied at an application rate selected from between 0.5 kg and 1.5 kg per square metre of pre-prepared surface.
  • the method further comprising the steps of:
  • thermally curing the thermally curable dielectric coating so as to seal the surface of the electrically-conductive layer, and form an electrically- conductive coating with an electrically-insulative surface.
  • the thermally curable dielectric coating is substantially volatile-free (100% solids) and is a 2-part thermally curable material.
  • the thermally curable dielectric coating is preferably applied in liquid form.
  • the dried electrically-conductive layer remains sorbent at the time of performing step d), such that the thermally curable dielectric coating is at least partially absorbed and/or adsorbed into the dried electrically- conductive layer.
  • a composite with a uniform structure and high conductivity is preferably obtained.
  • the desired uniform structure and high conductivity is obtained when the electrically-conductive carbon allotrope comprises graphene platelets and the thermally-conductive powder comprises ferrosilicon.
  • the resulting composite is preferably easily mixed with aqueous polymeric binders, forming a mixture suitable for application to a prepared surface.
  • the conductive strips comprise copper.
  • the conductive strips each comprise a conductive strip width selected from between 10 mm and 20 mm, and is most preferably 12.5 mm.
  • the conductive strip width of the plurality of conductive strips is the same.
  • the conductive strip width of the plurality of conductive strips may be varied.
  • flat conductive wires may be employed.
  • the flat conductive wires comprise copper.
  • a conductive coating is formed.
  • a dielectric coating is preferably applied. This dielectric coating is preferably partially absorbed by/into and/or adsorbed onto the conductive coating, thus forming a fused coating with high dielectric properties on the surface.
  • the coating is generating heat through electrically-resistive heating.
  • the resultant heating is highly efficient and has a power consumption of less than about 180 Watts/square metre to heat the coating up to about 32 degrees Celsius.
  • the surface to be treated may comprise one or more selected from the group: a floor or wall surface; an underside of a floor covering; a removable floor underlayment.
  • the surface to be treated may be any suitable surface required to radiate heat generated by electrical conduction.
  • the electrically-resistive heating element has an energy efficiency (Pt/P) of 0.90 to 1.00. It is thought that in today's conventional convection or oil heaters, the value of Pt/P is about 0.8-0.9. Determination of the energy efficiency of the coating is carried out by measuring the electricity consumption and measuring the heat produced in a conventional unit of time. The amount of heat produced is the sum of the amount of heat spent on heating the base layer (the electrically- conductive layer) of the coating, heating the ambient air and heating the surface of the coating. The ratio of the produced thermal power (Pt - in Watts) to the electrical power consumed for heating (P - in Watts), is an indicator of the energy efficiency (Pt/P).
  • FIG. 1 shows a sectional view of an example embodiment of an electrically- conductive coating in accordance with the second aspect of the present invention, comprising an electrically-conductive coating composition according to the first aspect of the present invention
  • FIG. 2 shows a perspective view of the example embodiment of FIG. 1 ;
  • FIG. 3 shows a schematic view of an example underfloor heating system in accordance with the third aspect of the present invention employing a electrically- conductive coating in accordance with the second aspect of the present invention
  • FIG. 4 shows a flow diagram describing an example embodiment of a method according to the third aspect of the present invention.
  • FIG. 1 a sectional view of an electrically-conductive coating 10 according to the second aspect of the present invention is shown.
  • the coating 10 forms a planar coating on a floor 12.
  • the floor surface 14 is pre-prepared with a network of elongate copper strips 16, over which a liquid-applied coating composition 18 according to the first aspect of the present invention is layered prior to drying.
  • the liquid-applied composition 18 comprises nanoplatelets of an electrically-conductive carbon allotrope (in this case graphene nanoplatelets), and a thermally-conductive powder (in this case atomised ferrosilicon) suspended in a water-borne polymeric binder (in this case a polyurethane based polymeric binder).
  • the upper surface 20 of the dried composition 18 is layered with a 2-part thermosettable dielectric layer 22 comprising a poly-urea composition having an aliphatic poly-isocyanate component and a poly-aspartic acid ester component.
  • the thermally cured dielectric layer 22 forms an insulative surface 24 of the coating 10.
  • a perspective view of the coating 10 is shown in FIG. 2.
  • the graphene nanoplatelets in the electrically-conductive composition 18 have a thickness of less than 5 nm and a size of less than 50 microns, and the atomised ferrosilicon comprises a particle size of between 50 microns and 200 microns.
  • the nanoplatelets and powder are distributed evenly in the polymeric binder to form a homogeneous mixture.
  • the ferrosilicon and graphene are present in a weight ratio of 10 : 1 respectively, and together constitute 70 weight percent of the aqueous mixture.
  • the network of copper strips have a width of 12.5 mm.
  • a coating such as the embodiment 10 shown in FIG. 1 and FIG. 2 would form part of an electrical heating system, an example 30 of which can be seen in the schematic view provided in FIG. 3.
  • the network of copper strips 32 are embedded within the electrically-conductive layer 34 formed using a composition according to the first aspect of the present invention.
  • the strips 32 are electrically connected to one another at a first end 36.
  • the strips 32 are connected to a power supply 40 arranged to provide an electrical current to the strips 32.
  • electricity is distributed about the electrically-conductive layer 34 by the graphene nanoplatelets therein. Resistive heat generated as a result is maintained and distributed by the thermally- conductive ferrosilicon powder.
  • the dielectric layer 42 provides an electrically- insulative surface such that the coating layer is made safe and efficient. As such an electrically-conductive heating system is provided which is easily applied whilst affording enhanced energy efficiency and reduced running costs.
  • FIG. 4 a flow chart is shown describing an example method of manufacturing an electrically-resistive heating element 50 according to the fourth aspect of the present invention, the method comprising the steps of: a) providing a pre-prepared surface by applying a network of self-adhesive, conductive copper strips or wires to a surface to be treated 52;
  • the electrically-resistive heating element manufactured is substantially the same as that described 10 in relation to FIG. 1 and FIG. 2, and the aqueous mixture of an electrically-conductive coating composition is therefore equal to that of the composition 18 therein.
  • the method 50 in the example embodiment shown also comprises the steps of: d) applying a thermally curable dielectric coating to the dried electrically- conductive layer 58; and
  • thermally curing the thermally curable dielectric coating so as to seal the surface of the electrically-conductive layer, and form an electrically- conductive coating with an electrically-insulative surface 60.
  • a power supply is connected to the conductive copper strips, and an electrical current applied by the power supply to the strips such that electrically-resistive heating is performed.
  • Example 1 To obtain a conductive/heating coating according to the second aspect of the present invention, an electrically-conductive composition mixture is prepared according to the first aspect: 240 grams of aqueous graphene paste with a graphene content of 25.5%; 54.4 grams of acrylic dispersion; 54.4 grams of SBR dispersion (product discussed in glossary below); 708 grams of ferrosilicon powder. The resulting mixture is thoroughly mixed for 5 minutes. After that, the resulting mixture is applied evenly over an area of 1 square meter with copper conductors. The layer is dried for 6-8 hours.
  • a dielectric layer is prepared, using poly-aspartic which is applied to the resulting electrically-conductive layer at an application rate of 320 grams per square meter.
  • the drying time of the poly-aspartic layer is 1 -1.5 hours.
  • the electrical resistivity of the obtained combined coating is 330-360 Ohms/square metre.
  • the power consumption for heating the coating to 32 degrees Celsius is 130-150 Watts/square meter.
  • the energy efficiency (Pt/P) is 0.99.
  • an electrically-conductive composition mixture is prepared according to the first aspect: 302 grams of aqueous graphene paste with a graphene content of 25.5%; 93.2 grams of acrylic dispersion; 40.0 grams of SBR (product discussed in glossary below) dispersion; 800 grams of ferrosilicon powder. The resulting mixture is thoroughly mixed for 5 minutes. After that, the resulting mixture is applied evenly over an area of 1 square meter with copper conductors. The layer is dried for 6-8 hours.
  • a dielectric layer is prepared, using poly-aspartic which is applied to the resulting electrically-conductive layer at an application rate of 300 grams per square meter.
  • the drying time of the poly-aspartic layer is 1 -1.5 hours.
  • the electrical resistivity of the obtained combined coating is 600-650 Ohms/square metre.
  • the power consumption for heating the coating to 32 degrees Celsius is 160-180 Watts/square meter.
  • the energy efficiency (Pt/P) is 0.98.
  • an electrically-conductive composition mixture is prepared according to the first aspect: 225 grams of aqueous graphene paste with a graphene content of 25.5%; 102 grams of acrylic dispersion (an off-the-shelf white primer comprising titanium dioxide microspheres); 606 grams of ferrosilicon powder. The resulting mixture is thoroughly mixed for 5 minutes. After that, the resulting mixture is applied evenly over an area of 1 square meter with copper conductors. The layer is dried for 6-8 hours.
  • a dielectric layer is prepared, using poly-aspartic which is applied to the resulting electrically-conductive layer at an application rate of 350 grams per square meter.
  • the drying time of the poly-aspartic layer is 1 -1.5 hours.
  • the electrical resistivity of the obtained combined coating is 800 Ohms/square metre.
  • the power consumption for heating the coating to 32 degrees Celsius is 160-180 Watts/square meter.
  • the energy efficiency (Pt/P) is 0.99.
  • an electrically-conductive composition mixture is prepared according to the first aspect: 225 grams of aqueous graphene paste with a graphene content of 25.5%; 100 grams of SBR dispersion (product discussed in glossary below); 605 grams of ferrosilicon powder. The resulting mixture is thoroughly mixed for 5 minutes. After that, the resulting mixture is applied evenly over an area of 1 square meter with copper conductors. The layer is dried for 6-8 hours. After drying, a dielectric layer is prepared, using poly-aspartic which is applied to the resulting electrically-conductive layer at an application rate of 350 grams per square meter. The drying time of the poly-aspartic layer is 1 -1.5 hours.
  • the electrical resistivity of the obtained combined coating is 750-770 Ohms/square metre.
  • the power consumption for heating the coating to 32 degrees Celsius is 150-170 Watts/square meter.
  • the energy efficiency (Pt/P) is 0.99.
  • Ferrosilicon powder Atomised Ferrosilicon 15% (Cyclone 60) - M&M Alloys Ltd. Poly-aspartic coating - MS 870, lOBAC Ltd.
  • Example embodiments such as those described in FIG. 1 to FIG. 4, will be appreciated having an electrically-conductive composition and/or eventual coating as described in any of Examples 1 to 4.

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Abstract

La présente invention concerne une composition de revêtement électroconductrice destinée à être utilisée pour fournir une surface chauffée électriquement. Le revêtement comprend un allotrope de carbone électroconducteur ; une poudre thermiquement conductrice ; et un liant polymère à base d'eau. Le revêtement de la présente invention vise à fournir un système de chauffage à sec qui offre une facilité et une simplicité d'installation tout en offrant une efficacité énergétique améliorée et des coûts d'utilisation réduits.
PCT/GB2020/050995 2019-04-30 2020-04-22 Système de revêtement mural ou de sol chauffé WO2020221987A1 (fr)

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CN113355016A (zh) * 2021-07-01 2021-09-07 江苏华晟国联科技有限公司 一种水性石墨烯导电储能发热防腐涂料及其制备方法

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CN114686293B (zh) * 2022-03-18 2023-03-10 煤炭科学技术研究院有限公司 一种耐高硬水液压支架浓缩液及其制备方法

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US20160360616A1 (en) * 2008-07-01 2016-12-08 Aruna Zhamu Patterned nano graphene platelet-based conductive inks
GB2537214A (en) * 2015-02-18 2016-10-12 Xefro Ip Ltd Heaters
CN107384135A (zh) * 2017-09-07 2017-11-24 深圳市嘉达高科产业发展有限公司 导热涂料及其制备方法
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CN111171378A (zh) * 2020-02-19 2020-05-19 青岛瑞利特新材料科技有限公司 一种碳纳米复合硅铁粉的制备方法和应用
CN113355016A (zh) * 2021-07-01 2021-09-07 江苏华晟国联科技有限公司 一种水性石墨烯导电储能发热防腐涂料及其制备方法

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