Carbon composite composition and carbon heater manufactured using the same

• US 11,097,985 B2
• Filed: 05/09/2018
• Issued: 08/24/2021
• Est. Priority Date: 05/10/2017
• Status: Active Grant

• Current Assignee: Industry Foundation Of Chonnam National University (Chonnam National University), LG Electronics, Inc. (LG Corporation)
• Original Assignee: LG Electronics, Inc. (LG Corporation)
• Inventors: Lee, Youngjun, Yang, Kap Seung, Kim, Sang Wan
• Primary Examiner(s): Gregorio, Guinever S
• Application Number:
  US15/975,348
• Publication Number:
  US 20180327323A1
• Time in Patent Office: 1,203 Days
• Field of Search: None
• CPC Class Codes: C04B 2235/3217 Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
• CPC Class Codes: C04B 2235/3418 Silicon oxide, silicic acids, or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint glass constituents C04B2235/36
• CPC Class Codes: C04B 2235/3826 Silicon carbides
• CPC Class Codes: C04B 2235/425 Graphite
• CPC Class Codes: C04B 2235/6025 Tape casting, e.g. with a doctor blade
• CPC Class Codes: C04B 35/565 based on silicon carbide
• CPC Class Codes: C04B 35/6303 Inorganic additives
• CPC Class Codes: C04B 35/63476 Phenol-formaldehyde condensation polymers
• CPC Class Codes: C08K 3/04 Carbon
• CPC Class Codes: C08L 61/06 of aldehydes with phenols
• CPC Class Codes: H05B 3/145 Carbon only, e.g. carbon black, graphite
• CPC Class Codes: H05B 3/148 Silicon, e.g. silicon carbide, magnesium silicide, heating transistors or diodes
• CPC Class Codes: H05B 3/64 using ribbon, rod, or wire heater

Abstract

A carbon composite composition and a carbon heater are provided. The carbon composite composition may include a phenolic resin as a binder, a lubricant, and a base material that determines a specific resistance of a resistance heating element at a high temperature. The carbon composite composition may prevent a dielectric breakdown, a spark and plasma from occurring in a carbon heater, and may improve radiation efficiency of the carbon heater.

Claims

1. A carbon composite composition, comprising:

a binder comprising a phenolic resin;

a lubricant;

a base material consisting of silicon carbide (SiC), the base material determining a specific resistance of a resistance heating element at a high temperature, wherein the SiC is present in an amount of 50 to 70%, based on a total weight of the composition; and

a specific resistance controlling agent comprising silicon oxide (SiO₂).

2. The carbon composite composition according to claim 1, wherein the SiO₂ is present in an amount of 24 wt. % or less, based on the total weight of the composition.

3. The carbon composite composition according to claim 1, wherein the phenolic resin is a novolac resin.

4. The carbon composite composition according to claim 3, wherein the novolac resin is present in an amount of 15 to 30 wt. %, based on the total weight of the composition.

5. The carbon composite composition according to claim 1, wherein the composition does not comprise a curing agent of hexamine for curing the phenolic resin.

6. The carbon composite composition according to claim 5, wherein the lubricant acts as a curing agent of the phenolic resin.

7. The carbon composite composition according to claim 6, wherein the lubricant is graphite.

8. The carbon composite composition according to claim 7, wherein the graphite is present in an amount of 0.1 to 10 wt. %, based on the total weight of the composition.

13. A carbon heater comprising the composition of claim 1.

9. A carbon composite composition, comprising:

a binder comprising a novolac resin;

a lubricant comprising graphite; and

a base material consisting of silicon carbide (SiC), the base material determining a specific resistance of a resistance heating element at a high temperature, wherein the SiC is present in an amount of 50 to 70%, based on a total weight of the composition; and

a specific resistance controlling agent comprising silicon oxide (SiO₂).

10. The carbon composite composition according to claim 9, wherein the novolac resin is present in an amount of 15 to 30 wt. %;

and the graphite is present in an amount of 0.1 to 10 wt. %, based on the total weight of the composition.

11. The carbon composite composition according to claim 9, wherein the composition does not comprise a curing agent of hexamine for curing the phenolic resin.

12. The composite for carbon composite according to claim 9, wherein the SiO₂ is present in an amount of 24 wt. % or less, based on the total weight of the carbon composite composition.

14. A carbon heater comprising the composition of claim 9.