Multifunctional assemblies

• US 11,438,973 B2
• Filed: 04/03/2015
• Issued: 09/06/2022
• Est. Priority Date: 04/10/2014
• Status: Active Grant

• Current Assignee: Metis Design Corporation
• Original Assignee: Metis Design Corporation
• Inventors: Kessler, Seth S., Thomas, Gregory A., Dunn, Christopher T., Borgen, Michael, Wardle, Brian L.
• Primary Examiner(s): Ross, Dana
• Assistant Examiner(s): Mills, Jr., Joe E
• Application Number:
  US14/678,066
• Publication Number:
  US 20160302264A1
• Time in Patent Office: 2,713 Days
• Field of Search: 219645, 219650, 219667, 219654, 219554, 219538, 219552
• CPC Class Codes: H01B 1/04 mainly consisting of carbon-silicon compounds, carbon or silicon
• CPC Class Codes: H01C 13/00 Resistors not provided for elsewhere
• CPC Class Codes: H01G 4/33 Thin- or thick-film capacitors thin- or thick-film circuits H01L27/00; capacitors without a potential-jump or surface barrier specially adapted for integrated circuits, details thereof, multistep manufacturing processes therefor H01L28/40
• CPC Class Codes: H05B 1/0236 for vehicles
• CPC Class Codes: H05B 2203/011 Heaters using laterally extending conductive material as connecting means
• CPC Class Codes: H05B 2203/013 Heaters using resistive films or coatings
• CPC Class Codes: H05B 2203/016 Heaters using particular connecting means
• CPC Class Codes: H05B 2203/017 Manufacturing methods or apparatus for heaters
• CPC Class Codes: H05B 2214/02 Heaters specially designed for de-icing or protection against icing
• CPC Class Codes: H05B 2214/04 Heating means manufactured by using nanotechnology
• CPC Class Codes: H05B 3/145 Carbon only, e.g. carbon black, graphite
• CPC Class Codes: H05B 3/20 Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater H05B3/62, H05B3/68, H05B3/78, H05B3/84 take precedence
• CPC Class Codes: H05B 3/265 the insulating base being an inorganic material, e.g. ceramic H05B3/262 takes precedence
• CPC Class Codes: H05B 3/267 the insulating base being an organic material, e.g. plastic H05B3/262 takes precedence
• CPC Class Codes: H05B 6/101 for local heating of metal pieces

Abstract

A multifunctional assembly having a resistive element a conductive element in electrical communication with the resistive element, the conductive element defining at least one of a plurality of multifunctional zones of the resistive element, wherein the conductive element is configured to direct a flow of electricity across at least one of the plurality of multifunctional zones of the resistive element in a preselected manner.

Claims

1. A method for manufacturing an object using a stacked multifunctional assembly, the method comprising:

integrating a multifunctional assembly onto an object having an integral polymer matrix, the multifunctional assembly having a stacked, layered structure including at least;

a first resistive layer having a carbon nanotube (CNT) network in sheet form,

a first conductive layer stacked on the first resistive layer, and

a first pair of insulating layers including a first insulating layer stacked on and disposed across the first resistive layer and a second insulating layer stacked on and disposed across the first conductive layer on a side opposing the first resistive layer;

coupling a voltage source or a current source to the first conductive layer;

flowing electrical current through the first resistive layer so as to generate heat; and

using the generated heat to form, heat treat or cure the integral polymer matrix of the object.

2. The method of claim 1, wherein flowing electrical current through the resistive layer includes driving electrical current through the resistive layer of the multifunctional assembly via contactless coupling to breakout points of the multifunctional assembly including inductive charging or receiving elements.

10. The method of claim 1, wherein flowing electrical current through the first resistive layer includes flowing electrical current through the carbon nanotube (CNT) network.

3. An assembled object comprising:

an integral polymer matrix forming a portion of the assembled object, and

a multifunctional assembly having a stacked, layered structure including at least;

a first resistive layer,

a first conductive layer electrically coupled to and stacked on the first resistive layer, and

a first pair of insulating layers including a first insulating layer stacked on and disposed across the first resistive layer and a second insulating layer stacked on and disposed across the first conductive layer on a side opposing the first resistive layer,

wherein the assembled object is formed by flowing electrical current through the resistive layer via the first conductive layer so as to generate heat and using the generated heat to form, heat treat or cure the integral polymer matrix of the assembled object.

4. The object of claim 3, wherein the multifunctional assembly further includes breakout points which include inductive charging or receiving elements for enabling contactless driving of electrical energy through the resistive layer of the multifunctional assembly thereby enabling contactless generation of heat.

11. The assembled object of claim 3, wherein the first resistive layer includes a carbon nanotube (CNT) network.

5. A system comprising:

an object formed in part from an integral polymer matrix, the object incorporating a multifunctional assembly having a stacked, layered structure including at least;

a first resistive layer,

a first conductive layer electrically coupled to and stacked on the first resistive layer, and

a first pair of insulating layers including a first insulating layer stacked on and disposed across the first resistive layer and a second insulating layer stacked on and disposed across the first conductive layer on a side opposing the first resistive layer; and

a control system operationally coupled to the resistive layer via the conductive layer and configured or programmed to drive the resistive layer with electrical energy to maintain or change a temperature to form, heat treat or cure the integral polymer matrix of the object.

6. The system of claim 5, further comprising a sensor for providing temperature feedback for at least one of the portion of the object or its surroundings.

7. The system of claim 6, wherein the control system is configured or programmed to adjust the electrical energy based on the temperature feedback.

8. The system of claim 5, wherein the multifunctional assembly further includes breakout points which include inductive charging or receiving elements for enabling contactless driving of electrical energy through the resistive layer of the multifunctional assembly thereby enabling contactless generation of heat.

9. The system of claim 5, wherein the object formed incorporating the stacked multifunctional assembly is a tool adapted for use in a curing or other heat treatment process to generate heat in a controllable and configurable manner so as to enable forming, curing or treating a different object in contact with the tool, the different object having a polymer matrix.

12. The system of claim 5, wherein the first resistive layer includes a carbon nanotube (CNT) network.

13. A system comprising:

a manufacturing tool adapted for use in a forming, curing, or heat treating process for an object having a polymer matrix included therein, the tool being in contact with the object during the forming, curing or heat treating process, the tool formed incorporating a multifunctional assembly having a stacked, layered structure including at least;

a first resistive layer having a carbon nanotube (CNT) network in sheet form,

a first conductive layer electrically coupled to and stacked on the first resistive layer, and

a first pair of insulating layers including a first insulating layer stacked on and disposed across the first resistive layer and a second insulating layer stacked on and disposed across the first conductive layer on a side opposing the first resistive layer; and

a control system operationally coupled to the resistive layer via the conductive layer and configured or programmed to drive the resistive layer with electrical energy to generate heat in a controllable and configurable manner so as to enable forming, curing, or heat treating the polymer matrix of the object.

14. The system of claim 13, further comprising a first plurality of electrical breakout points to couple the first conductive layer to an environment exterior to the first and second insulating layers.

15. The system of claim 14, wherein the first plurality of electrical breakout points includes contactless coupling elements.

16. The system of claim 15, wherein the contactless coupling elements include inductive charging or receiving elements.

17. The system of claim 13, wherein the sheet form of the CNT network is an isolated ply.