Industrial technological innovation
Conductive and resistive carbon pastes for a wide range of electrical products.
Industrial technological innovation
Conductive and resistive carbon pastes for a wide range of electrical products.
Ongoing investment in green building projects, combined with a focus on smart city programs and initiatives in many countries, has resulted in the construction of a large number of residential and commercial properties. Underfloor heating systems can be easily installed in new rooms, covering the desired area to minimize heat loss and provide cost savings. Optimized heating, coupled with significant reductions in installation time and upfront costs, could help the industry grow in the future if it were based on a product made in Russia. A significant share of the market for underfloor heating systems is occupied by private houses, and the use of large areas of heat transfer would help the spread of Smart Home systems, which would provide not only a comfortable stay in the room, but also, according to various scientists, energy savings of up to 40%. The absence in Russia of its own production of a wide range of carbon paste does not allow development in other commercial areas. For example, using this technology, it is possible to organize the production of anti-icing systems for roofs and the adjacent territory, organize the production of thermal curtains in the form of curtains and many other household and industrial appliances.
The use of carbon-based materials is increasing every year all over the world. One of the uses of carbon is the manufacture of conductive and resistive materials in instrumentation. For this, carbon pastes with various electrophysical characteristics are used, and the properties of the pastes are selected individually for each product. Basically, carbon pastes are used in the electronics industry, in devices operating at low voltages and at low current loads. One of the most common uses for carbon fiber is in building heating systems. For the first time in mass production, a carbon-based heating element was supplied in South Korea, Korean film underfloor heating is a global brand that sells well all over the world. In Russia, similar infrared heating systems are produced on carbon fibers, foil, but in terms of cost, range and technical capabilities, they are seriously inferior to the Korean product.
At the same time, the Korean heating element has a number of significant problems that arise during operation: low range of use; heaters are afraid of ultraviolet radiation; I work only up to a temperature of 60 ° C; can not work when connected in series at large current loads; have a relatively low specific power; the most reliable and common hot melt adhesive based on ethylene vinyl acetate (EVA) cannot be used in production. All resistive pastes have high resistance on their surface. Silver paste is used to "connect to electricity". Silver paste is very expensive. To keep costs down, manufacturers are thinning the silver layer and placing copper foil on top. The estimated cost of the applied amount of silver paste outweighs the cost of resistive carbon paste by almost 5 times. Korean heating elements are a mass product, for which they use carbon paste made in Japan.
At the moment, neither on the territory of South Korea, nor on the territory of Russia there is no technology, using which it would be possible to massively produce conductive or resistive elements in a wide range of resistivity with high quality.
These technologies are possessed by manufacturers in Japan, England and the United States. Working with their materials, we studied their physical, technical and rheological characteristics and not only were able to repeat them, but showed that it is possible to improve technical characteristics and reduce the cost, as well as significantly expand their range of applications.
How do we solve this problem?
The identified problems are solved by using a patented technology for the production of carbon paste and heating elements.
Thanks to many years of experience in this scientific field, we have optimized the compositions of carbon paste compositions consisting of a mixture of fine and ultrafine powders of graphite and carbon black, a mixture of ultrafine metal powders mainly of Ni3B, Ni, Cr, Al and a polymer binder, and the ultrafine powders are uniformly are spatially distributed between the functional phases of these compositions, which ensures the stability of the electro-physical characteristics, an increase in the value of the specific power.
The use of our heating elements allows you to solve the problem of controlling the heating system without complex external control devices. The structure of the heating element consists of semiconductor materials, in the interlayer space of which ultradispersed powders of Ni3B, Ni, Cr, Al are embedded, which simultaneously control and control each heating point localized. The materials used for the manufacture of conductive and protective layers are corrosion-resistant and chemically resistant to a wide range of aggressive media. The heating element gives out at each heating point exactly as much heat energy as is necessary to maintain the set parameter. Compared to other technologies for mass production of large area heating elements, the developed process is cheap and highly efficient. Moreover, in terms of technical characteristics, heating elements are not only not inferior, but also significantly surpass the best world analogues. To expand the range of applications, increase the specific power, all developers are conducting research in the field of determining and creating the dependence of the active resistance of the heater and the temperature on its surface. Moreover, this dependence can be either a linear or non-linear function. The theoretical calculations carried out by the project team in this area have been confirmed by practical application, which shows that, depending on this parameter, the efficiency of the system increases by several tens of percent. The project team has developed a technology that allows you to set this dependence over a wide range of powers and temperatures.
In this case, the temperature dependence of the resistance of the heating element is not a linear function, but changes its value in a certain temperature range. At the moment, work has been completed on the creation of a universal homogenizer, which will be used in the mass production of heating elements. A wide range of resistance ratings allowed us to develop a paste with similar characteristics with structures that are used for pipe frost protection systems, for roof and building de-icing systems. As noted above, our technology differs from the existing ones in its performance and lower cost, while with better electrical characteristics, which allows us to use our carbon paste for the manufacture of current-carrying paths in electrical products and the creation of resistive elements.
The solution to one of the current tasks that are posed in this project will help to increase the range of application of carbon paste, expand the range of import-substituting products. The produced carbon paste can be used for the mass production of heating elements, such as film heating elements for underfloor heating, painting heaters, anti-icing systems, agricultural dryers, etc.
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