Carbon Nanotube Thin Film Laminate Resistive Heater

Patent metadata

Field	Value
Publication number	US-2016379740-A1
Application number	US-201615263382-A
Country	US
Kind code	A1
Filing date	Sep 13, 2016
Priority date	Nov 17, 2010
Publication date	Dec 29, 2016
Grant date	—

Abstract

Laminated resistive heaters comprising a carbon nanotube layer are described. The invention also includes methods of making laminated resistive heaters and applications using the resistive heaters.

First claim

1 - 15 . (canceled)

16 . A method of making a laminated resistive heater, comprising: providing a polymeric base layer comprising peaks; forming a carbon nanotube (CNT) resistive heating layer having an interior that is substantially polymer-free disposed on the surface of the polymeric base film resistive heating layer, providing first and second electrical leads connected to the CNT layer; providing a protective polymer layer disposed on a side of the CNT layer opposite the side facing the base layer, wherein the protective layer adheres to the base film at the peaks on the polymeric base layer.

17 . A laminated resistive heater made by the method of claim 16 .

18 . The method of claim 16 further comprising a step of applying a pressure sensitive adhesive (psa) disposed on a side of the polymeric base layer opposite the side on which the CNT layer is disposed.

19 . The method of claim 16 wherein the step of forming a carbon nanotube (CNT) resistive heating layer comprises applying a carbon nanotube (CNT) dispersion onto the surface of the polymeric base layer.

20 . The method of claim 16 wherein the polymeric base layer is an embossed layer.

21 . The method of claim 16 wherein the peaks are wiped clean prior to applying the protective polymer layer.

22 . The method of claim 16 wherein the first and second electrical leads are applied after the CNT layer has been applied.

23 . The method of claim 16 wherein the CNT layer has an interior that comprises 5 wt % or less of polymer.

24 . The method of claim 19 wherein the CNT dispersion is applied by a coating method selected from the group consisting of: spraying, roll-coating, gravure printing, flexography, brush application, and spin-coating.

25 . The method of claim 16 wherein the CNT layer has a thickness in the range from 0.05 μm to 100 μm.

26 . The method of claim 16 wherein the protective polymeric layer has a thickness of 250 nm to 50 μm.

27 . The method of claim 16 wherein the application of the protective polymeric layer results in less than a 10% change in resistance.

28 . The method of claim 19 wherein the polymeric base layer is treated, prior to applying the CNT dispersion, with a treatment selected from the group consisting of: corona treatment, plasma treatment, and gas flame treatment.

29 . The method of claim 19 wherein the polymeric base layer is corona treated prior to applying the CNT dispersion.

30 . The method of claim 29 wherein the polymeric base layer is sanded prior to being corona treated.

Assignees

• Battelle Memorial Institute

Inventors

• Heintz Amy M
• Mitchell Katherine P
• Burton Brett R
• Feier Ioan I
• Lastrapes Timothy J
• Muszynski Beth

Classifications

• H05B2214/04

  Heating means manufactured by using nanotechnology · CPC title

• H01C17/065 Primary

  by thick film techniques, e.g. serigraphy · CPC title

• H05B3/145

  Carbon only, e.g. carbon black, graphite · CPC title

• Y10T29/49083

  Heater type · CPC title

• H05B2203/013

  Heaters using resistive films or coatings · CPC title