Additively manufactured composite heater

Patent metadata

Field	Value
Publication number	US-2018235030-A1
Application number	US-201815889283-A
Country	US
Kind code	A1
Filing date	Feb 6, 2018
Priority date	Feb 15, 2017
Publication date	Aug 16, 2018
Grant date	—

Abstract

An composite heater is disclosed. The heater may include a base additively manufactured from a first matrix material, and a heating element additively manufactured adjacent the base from a second matrix material and an electrically and thermally conductive fiber that is at least partially encased in the second matrix material. The heater may also include a control mechanism configured to selectively complete a circuit between a power supply and the electrically and thermally conductive fiber.

First claim

What is claimed is:

1 . A heating element, comprising:
a matrix material; an electrically and thermally conductive fiber that is at least partially encased in the matrix material; and an electrically conductive fiber that extends into the matrix material and connects with the electrically and thermally conductive fiber, wherein a resistance of the electrically and thermally conductive fiber is higher than a resistance of the electrically conductive fiber.

2 . The heating element of claim 1 , wherein the matrix material is a thermoset polymer.

3 . The heating element of claim 1 , wherein the electrically and thermally conductive fiber is continuous throughout the matrix material.

4 . The heating element of claim 3 , further including electrically and thermally conductive particles suspended in the matrix material.

5 . The heating element of claim 1 , wherein the electrically and thermally conductive fiber includes only particles suspended in the matrix material.

6 . The heating element of claim 1 , wherein the matrix material has a porosity less than about 60%.

7 . The heating element of claim 1 , wherein:
the electrically and thermally conductive fiber is a first fiber; and the heating element further includes a second electrically and thermally conductive fiber that is at least partially encased in the matrix material and connected to the electrically conductive fiber.

8 . The heating element of claim 7 , wherein:
the first fiber forms a first circuit; and the second electrically and thermally conductive fiber forms a second circuit.

9 . The heating element of claim 7 , wherein:
the first fiber is joined serially with the second electrically and thermally conductive fiber; and the second electrically and thermally conductive fiber has at least one of a diameter, cross-sectional shape, and material consist that is different from the first fiber.

10 . The heating element of claim 9 , further wherein the first fiber is joined with the second electrically and thermally conductive fiber via a solder paste.

11 . A composite heater, comprising:
a base additively manufactured from a first matrix material; a heating element additively manufactured adjacent the base from a second matrix material and an electrically and thermally conductive fiber that is at least partially encased in the second matrix material; and a control mechanism configured to selectively complete a circuit between a power supply and the electrically and thermally conductive fiber.

12 . The composite heater of claim 11 , wherein a thermal conductivity of the first matrix material is lower than a thermal conductivity of the second matrix material.

13 . The composite heater of claim 12 , wherein:
the first matrix material has a porosity greater than about 60%; and the second matrix material has a porosity less than about 60%.

14 . The composite heater of claim 12 , wherein the electrically and thermally conductive fiber is continuous throughout the second matrix material.

15 . The composite heater of claim 14 , further including electrically and thermally conductive particles suspended in the second matrix material.

16 . The composite heater of claim 12 , wherein the electrically and thermally conductive fiber includes only particles suspended in the second matrix material.

17 . The composite heater of claim 11 , wherein:
the base includes a recess; and the heating element is disposed in the recess.

18 . The composite heater of claim 11 , wherein the base is additively manufactured from a continuous fiber that is at least partially encased in the first matrix material and formed into a lattice structure.

19 . The composite heater of claim 11 , wherein the base is additively manufactured from a continuous fiber that is at least partially encased in the first matrix material and formed into an electromagnet.

20 . The composite heater of claim 11 , wherein the first and second matrix materials are thermoset polymers.

Assignees

• Cc3D Llc

Inventors

• Tyler Kenneth Lyle

Classifications

• H05B3/286 Primary

  the insulating material being an organic material, e.g. plastic · CPC title

• B29C64/165

  using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title

• B29K2101/10

  Thermosetting resins · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title