Heating element, manufacturing method thereof, composition for forming heating element, and heating apparatus

Patent metadata

Field	Value
Publication number	US-12041697-B2
Application number	US-202016919792-A
Country	US
Kind code	B2
Filing date	Jul 2, 2020
Priority date	Dec 8, 2016
Publication date	Jul 16, 2024
Grant date	Jul 16, 2024

Abstract

A heating element includes a plurality of matrix particles and a conductive inorganic filler disposed at interfaces between the plurality of matrix particles to provide a conductive network.

First claim

What is claimed is:

1. A composition for forming a heating element, the composition comprising matrix particles having positively or negatively charged surface, and a conductive inorganic filler.

2. The composition of claim 1 , wherein the matrix particles comprise a glass, an organic polymer, or any combination thereof.

3. The composition of claim 2 , wherein the glass is formed from a glass frit comprising at least one of a silicon oxide, a lithium oxide, a nickel oxide, a cobalt oxide, a boron oxide, a potassium oxide, an aluminum oxide, a titanium oxide, a manganese oxide, a copper oxide, a zirconium oxide, a phosphorus oxide, a zinc oxide, a bismuth oxide, a lead oxide, or a sodium oxide.

4. The composition of claim 2 , wherein the glass is formed from a glass frit comprising at least one of a zinc oxide-silicon oxide, a zinc oxide-boron oxide-silicon oxide, a zinc oxide-boron oxide-silicon oxide-aluminum oxide, bismuth oxide-silicon oxide-, a bismuth oxide-boron oxide-silicon oxide, a bismuth oxide-boron oxide-silicon oxide-aluminum oxide, a bismuth oxide-zinc oxide-boron oxide-silicon oxide, or a bismuth oxide-zinc oxide-boron oxide-silicon oxide-aluminum oxide compound.

5. The composition of claim 2 , wherein when the organic polymer is used, the organic polymer comprises at least one of a polyimide, a polyphenylenesulfide, a polybutylene terephthalate, a polyamideimide, a liquid crystalline polymer, a polyethylene terephthalate (PET), a polyphenylene sulfide, or a polyetheretherketone.

6. The composition of claim 1 , wherein the matrix particles have positively or negatively charged functional groups on the surfaces thereof.

7. The composition of claim 1 , wherein the matrix particles comprise at least one of hydroxide ion (OH − ), a sulfate ion (SO 4 2− ), a nitrate ion (NO 3 − ), an acetate ion (CH 3 COO − ), a permanganate ion (MnO 4 − ), a carbonate ion (CO 3 2− ), a sulfide ion (S 2− ), a chloride ion (Cl − ), a bromide ion (Br − ), or an oxide ion (O 2− ).

8. The composition of claim 1 , wherein the conductive inorganic filler is in a form of nano-sheets, nano-rods, or any combination thereof.

9. The composition of claim 1 , wherein the conductive inorganic filler is in a form of nano-sheets having a thickness of about 1 nanometer to about 1,000 nanometers.

10. The composition of claim 1 , wherein the conductive inorganic filler has an electrical conductivity of 1,250 Siemens per meter or greater.

11. The composition of claim 1 , wherein the conductive inorganic filler comprises at least one of an oxide, a boride, a carbide, and a chalcogenide.

12. The composition of claim 11 , wherein
the oxide comprises RuO 2 , MnO 2 , ReO 2 , VO 2 , OsO 2 , TaO 2 , IrO 2 , NbO 2 , WO 2 , GaO 2 , MoO 2 , InO 2 , CrO 2 , RhO 2 , or any combination thereof,
the boride comprises Ta 3 B 4 , Nb 3 B 4 , TaB, NbB, V 3 B 4 , VB, or any combination thereof,
the carbide comprises Dy 2 C, Ho 2 C, or any combination thereof, and
the chalcogenide comprises AuTe 2 , PdTe 2 , PtTe 2 , YTe 3 , CuTe 2 , NiTe 2 , IrTe 2 , PrTe 3 , NdTe 3 , SmTe 3 , GdTe 3 , TbTe 3 , DyTe 3 , HoTe 3 , ErTe 3 , CeTe 3 , LaTe 3 , TiSe 2 , TiTe 2 , ZrTe 2 , HfTe 2 , TaSe 2 , TaTe 2 , TiS 2 , NbS 2 , TaS 2 , Hf 3 Te 2 , VSe 2 , VTe 2 , NbTe 2 , LaTe 2 , CeTe 2 , or any combination thereof.

13. The composition of claim 1 , further comprising at least one of a dispersion stabilizer, an oxidation stabilizer, a weather stabilizer, an antistatic agent, a dye, a pigment, or a coupling agent.

14. The composition of claim 13 , wherein when the dispersion stabilizer is used, the dispersion stabilizer comprises a low-molecular-weight amine compound, an amine oligomer, an amine polymer, or any combination thereof.

15. The composition of claim 1 , further comprising a binder,
wherein the binder comprises at least one of a cellulose polymer, a (meth)acrylic acid polymer, a styrene polymer, a polyvinyl resin, a (meth)acrylic (C1-C6 alkyl) ester polymer, a styrene-(meth)acrylic (C1-C6 alkyl) ester copolymer, a polyvinyl butyral, a polyvinyl alcohol, a polyethylene oxide, a polypropylene carbonate, a polymethyl (meth)acrylate, an ammonium (meth)acrylate, an Arabic gum, a gelatin, an alkyd resin, s butyral resin, s saturated ester polymer, a natural rubber, a silicone rubber, a fluorosilicone, a fluoroelastomer, a synthetic rubber, or any copolymer thereof.

16. The composition of claim 1 , wherein the composition comprises:
about 5% to about 99.9% by volume of the matrix particles and about 0.01% to about 95% by volume of the conductive inorganic filler, based on a total volume of the matrix particles and the conductive inorganic filler.

17. The composition of claim 1 , further comprising a solvent.

18. The composition of claim 17 , wherein the composition comprises:
about 5 parts to about 500 parts by volume of the solvent based on 100 parts by volume of the total volume of the functionalized matrix particles and the conductive inorganic filler.

19. A method of manufacturing a heating element, the method comprising:
coating the composition for forming a heating element of claim 1 on a substrate; and
heat-treating the coated substrate to provide the heating element.

20. The method of claim 19 , wherein the composition further comprises a solvent.

21. The method of claim 19 , wherein the coating is performed by spray coating.

22. The method of claim 19 , wherein the heat-treating is performed at a temperature of about 300° C. to about 1200° C.

23. A method of manufacturing a composition for forming a heating element of claim 1 , the method comprising:
functionalizing surfaces of matrix particles with positive charges or negative charges to have positively or negatively charged functional groups on the surfaces thereof; and
combining the surface-functionalized matrix particles and a conductive inorganic filler.

24. The method of claim 23 , wherein the surface-functionalized matrix particles and a conductive inorganic filler are further combined with solvent.

Assignees

• Samsung Electronics Co Ltd

Inventors

• Sohn Hiesang
• Kim Seyun
• Koh Haengdeog
• Kim Doyoon
• Mizusaki Soichiro
• Kim Jinhong
• Kim Hajin
• Bae Minjong
• Lee Changsoo

Classifications

• C03C8/04

  containing zinc · CPC title

• H05B3/26

  heating conductor mounted on insulating base {(for transparent areas H05B3/84, H05B3/86)} · CPC title

• H05B2203/013

  Heaters using resistive films or coatings · CPC title

• H05B3/146

  Conductive polymers, e.g. polyethylene, thermoplastics · CPC title

• H05B3/141

  Conductive ceramics, e.g. metal oxides, metal carbides, barium titanate, ferrites, zirconia, vitrous compounds · CPC title