Process of making conformable, low voltage, light weight joule heating elements

A method of making a low voltage joule heating element, conformable to its substrate, comprising:

• forming said joule heating element from carbon nanotubes (CNTs);
• wherein forming comprises dispersing the CNTs within a polymer solution to form a dispersed CNT polymer material, followed by curing the polymer solution;
• wherein the polymer solution includes a polymer dissolved in a non-volatile organic solvent that is soluble with both the polymer and the CNTs;
• and
• wherein the non-volatile organic solvent is selected from N-Methyl-2-pyrrolidone (NMP), acetone, an alcohol, tetrahydrofuran (THF), dichloromethane, and combinations thereof.

A method of making a low voltage joule heating element, conformable to its substrate, comprising:

• forming said joule heating element from carbon nanotubes (CNTs);
• wherein forming comprises dispersing the CNTs within a polymer solution to form a dispersed CNT polymer material, followed by curing the polymer solution;
• wherein forming comprises synthesizing the polymer solution component from a plurality of monomer precursors, of which at least one monomer contains dispersed CNTs;
• and
• wherein the monomer containing dispersed CNTs is ethylene glycol.

A method of making a low voltage joule heating element, conformable to its substrate, comprising:

• forming said joule heating element from carbon nanotubes (CNTs);
• wherein forming comprises dispersing the CNTs within a polymer solution to form a dispersed CNT polymer material, followed by curing the polymer solution;
• wherein the polymer solution includes a polymer dissolved in a non-volatile organic solvent that is soluble with both the polymer and the CNTs;
• and
• wherein the non-volatile organic solvent is selected from N-Methyl-2-pyrrolidone (NMP), acetone, an alcohol, tetrahydrofuran (THF), dichloromethane, and combinations thereof.

A method of making a low voltage joule heating element, conformable to its substrate, comprising:

• forming said joule heating element from carbon nanotubes (CNTs);
• adding a liquid, which is completely miscible with the non-volatile organic solvent yet immiscible to the CNT and polymer, to the dispersed CNT polymer solution to drive the separation of 40-90% of the original solvent content by mass from the CNT and polymer components, and resulting in a putty-like consistency that is viscous enough to be handled and shaped;
• and
• removing the remaining solvent after shaping to solidify the joule heating element in the desired geometry;
• wherein forming comprises dispersing the CNTs within a polymer solution to form a dispersed CNT polymer material, followed by curing the polymer solution;
• wherein the polymer solution includes a polymer dissolved in a non-volatile organic solvent that is soluble with both the polymer and the CNTs;
• and
• wherein removing the solvent includes passing an electric current through the mixture, supplied by an applied voltage from 1 V to 500 V.

A method of making a low voltage joule heating element, conformable to its substrate, comprising:

• forming said joule heating element from carbon nanotubes (CNTs);
• and
• installing electrical contacts to the joule heating element, the electrical contacts being configured to be coupled to an external power supply;
• wherein the electrical contacts comprise a carbon material;
• and
• wherein the carbon material is Bucky paper, a CNT/graphene composite solution, carbon fiber, carbon fiber veil, CNT thread, or wire.

A method of making a low voltage joule heating element, conformable to its substrate, comprising:

• forming said joule heating element from carbon nanotubes (CNTs);
• and
• installing electrical contacts to the joule heating element, the electrical contacts being configured to be coupled to an external power supply;
• wherein the electrical contacts comprise a carbon material;
• and
• wherein the electrical contacts comprise a conductive epoxy that contains metal, carbon-based conductive additives, or a combination thereof.

A method of making a low voltage joule heating element, conformable to its substrate, comprising:

• forming said joule heating element from carbon nanotubes (CNTs);
• and
• installing electrical contacts to the joule heating element, the electrical contacts being configured to be coupled to an external power supply;
• and
• enhancing the connection of the electrical contacts to the joule heating element material using a solder, a low-melting metal alloy, a conductive epoxy, or a combination thereof;
• wherein the electrical contacts comprise a carbon material;
• wherein the electrical contacts comprise a metal material.

A method of making a low voltage joule heating element, conformable to its substrate, comprising:

• forming said joule heating element from carbon nanotubes (CNTs);
• and
• installing electrical contacts to the joule heating element, the electrical contacts being configured to be coupled to an external power supply;
• wherein the electrical contacts comprise a carbon material;
• and
• wherein the electrical contacts have a conductive solution applied thereon to increase the electrical conductivity of the connection between the joule heating element and the electrical contacts.

A method of making a low voltage joule heating element, conformable to its substrate, comprising:

• forming said joule heating element from carbon nanotubes (CNTs);
• and
• shaping the dispersed CNT polymer composite material into a desired geometry for the joule heating element may be carried out by extrusion, rolling, pressing, molding or otherwise physically manipulating;
• and
• wetting a surface of the joule heating element with a solution to aid contact adhesion of the electrical contacts to the surface;
• wherein forming comprises dispersing the CNTs within a polymer solution to form a dispersed CNT polymer material, followed by curing the polymer solution.

A method of making a low voltage joule heating element, conformable to its substrate, comprising:

• forming said joule heating element from carbon nanotubes (CNTs);
• and
• functionalizing the CNTs;
• wherein functionalizing includes exposing the CNTs to atmospheric pressure plasma;
• and
• wherein the atmospheric pressure plasma comprises oxygen based atmospheric pressure plasma.

A method of making a low voltage joule heating element, conformable to its substrate, comprising:

• forming said joule heating element from carbon nanotubes (CNTs);
• and
• functionalizing the CNTs;
• wherein functionalizing includes exposing the CNTs to atmospheric pressure plasma;
• and
• wherein functionalizing includes exposing the CNTs to the atmospheric pressure plasma for a time of from 0.1 s to 50 s.

A method of making a low voltage joule heating element, conformable to its substrate, comprising:

• forming said joule heating element from carbon nanotubes (CNTs);
• and
• functionalizing the CNTs;
• wherein functionalizing includes exposing the CNTs to atmospheric pressure plasma;
• and
• wherein functionalizing includes exposing the CNTs to the atmospheric pressure plasma at a power of from 5 W to 500 W.