Methods for producing an electrically conductive material, electrically conductive material and emitter containing electrically conductive material

Patent metadata

Field	Value
Publication number	US-9269560-B2
Application number	US-201214237211-A
Country	US
Kind code	B2
Filing date	Jul 4, 2012
Priority date	Aug 5, 2011
Publication date	Feb 23, 2016
Grant date	Feb 23, 2016

Abstract

A method for manufacturing an electrically conductive material includes steps of: (a) providing a carbon fiber; (b) providing a plastic fiber that differs from the carbon fiber; (c) producing a mixture in the form of a two-dimensional mat from the carbon fiber and the plastic fiber; (d) drying the mixture, optionally; (e) consolidating the mixture; (f) cutting the mixture to size, optionally; (g) carbonizing the mixture, wherein the carbonized plastic fibers form a carbon-based matrix possessing electrical conductivity that at least partially surrounds the carbon fibers. Electrically conductive materials obtained by the method have an increased electrical resistance. An emitter is specified that contains a transparent or translucent housing and an electrically conductive material as above. These now allow emitters of virtually any length to be operated at customary line voltages.

First claim

We claim:

1. A method for manufacture of an electrically conductive material, the method comprising the steps of:
a) providing a carbon fiber;
b) providing a plastic fiber that differs from the carbon fiber;
c) producing a mixture in a form of a two-dimensional mat from the carbon fiber and the plastic fiber; wherein the mat comprises a multitude of single fibers that are deposited at random;
d) optionally drying the mixture;
e) consolidating the mixture;
f) optionally cutting the mixture to size; and
g) carbonizing the mixture, wherein the carbonized plastic fibers form a carbon-based matrix possessing electrical conductivity that at least partially surrounds the carbon fibers.

2. The method according claim 1 , wherein a mass fraction of carbon fibers, relative to the mixture, is from 1 mass % to 70 mass %.

3. The method according to claim 1 , wherein a fiber weight per unit area of the consolidated mixture is 75 g/m 2 to 500 g/m 2 .

4. The method according to claim 1 , wherein a length of the carbon fibers and plastic fibers in the mixture differs by maximally 50% relative to the length of the carbon fibers.

5. The method according to claim 1 , wherein a length of the carbon fibers or of the plastic fibers or both in the mixture is from 3 mm to 30 mm.

6. The method according to claim 1 , wherein the plastic fibers contain a thermoplastic material.

7. The method according to claim 6 , wherein thermoplastic material contains a material selected from polyethersulfone (PES), polyetheretherketone (PEEK), polyetherimide (PEI), polyethyleneterephthalate (PET), polyphthalamide (PPA), polyphenylenesulfide (PPS), polyimide (PI), and mixtures of at least two of these.

8. The method according to claim 1 , wherein another plastic fiber made of duroplastic material is used in addition to the plastic fiber made of thermoplastic material.

9. An electrically conductive material comprising a composite that contains:
a) a first carbon fiber and a further carbon fiber; and
b) a matrix that partly surrounds the first carbon fiber and the further carbon fiber each, wherein the electrical conductivity of the matrix is lower than that of the carbon fibers;

wherein, with respect to a sectional plane through the composite, of a total number of carbon fibers extending through the sectional plane, more than 20% of the carbon fibers extending through the sectional plane do not contact any other carbon fiber extending through the same sectional plane.

10. The electrically conductive material according to claim 9 , wherein the sectional plane is oriented to be orthogonal to a possible direction of current flow through the material.

11. The electrically conductive material according to claim 9 , having at least one of the following properties:
i. the matrix has a defined specific electrical conductivity;
ii. the matrix defines an orientation of the carbon fibers;
iii. the matrix defines a specific number of contact sites between carbon fibers ( 3 ); and
iv. the carbon fibers are distributed and/or oriented in the matrix in appropriate manner, such that a current flow through the material is forced to proceed at least through a portion of the matrix.

12. An emitter comprising:
a) a transparent or translucent housing; and
b) an electrically conductive material according to claim 9 , arranged in the housing.

13. The emitter according to claim 12 , wherein the electrically conductive material has appropriate flexibility, such that the electrically conductive material can be bent into a circle and over its entire length about a radius of 1.0 m, without fracturing the carbon fibers and/or the matrix and/or without separating the carbon fibers and the matrix.

14. The emitter according to claim 13 , wherein the flexibility is such that the electrically conductive material can be bent into a circle and over its entire length about a radius of 0.25 m, without fracturing the carbon fibers and/or the matrix and/or without separating the carbon fibers and the matrix.

15. The emitter according to claim 12 , wherein the electrical conductivity of the electrically conductive material, measured as electrical operating voltage per unit of length of the electrically conductive material, exceeds 150 V/m.

Assignees

• Klumpp Maike
• Linow Sven
• Heraeus Noblelight Gmbh

Inventors

• Klumpp Maike
• Linow Sven

Classifications

• H01K1/06 Primary

  Carbon bodies · CPC title

• H05B2203/017

  Manufacturing methods or apparatus for heaters · CPC title

• H05B3/0033

  Heating devices using lamps · CPC title

• H05B3/146

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

• H01K3/02

  Manufacture of incandescent bodies · CPC title