Search Results (140)

Polymer-based electrothermal composites (PECs) have been increasingly attracting attention in recent years owing to their flexibility, low density, and high electrothermal efficiency. However, although a large number of reviews have focused on flexible and transparent film heaters as well as polymer-based conductive composites, comprehensive reviews of polymer-based electrothermal composites remain limited. Herein, we provide a comprehensive review of recent advancements in polymer-based electrothermal materials. This review begins with an introduction to the electrothermal theoretical basis and the research progress of PECs incorporating various conductive fillers, such as graphene, carbon nanotubes (CNTs), carbon black (CB), MXenes, and metal nanowires. Furthermore, a critical discussion is provided to emphasize the factors influencing the electrothermal conversion efficiency of these composites. Meanwhile, the development of multi-functional electrothermal materials has been also summarized. Finally, the application progress, future prospects, limitations, and potential directions for PEC are discussed. This review aims to serve as a practical guide for engineers and researchers engaged in the development of polymer-based electrothermal composites. Full article

Thermal mass flow sensors (TMFS) are used to detect the flow rates of gases. TMFS elements are available in different technologies and, depending on the one used, the material choice of substrate, heater, and temperature sensors can limit their performance. In this work, a sensor element based on the Ensinger Microsystems Technology (EMST) is presented that uses PEEK as the substrate, nickel-chromium as the heater, and nickel as the temperature sensor material. The fabrication process of the element is described, the completion to a flow sensor with a control and readout circuit based on discharge time measurement with picosecond resolution is presented, and measurement results are shown, which are compared to sensors with a commercially available element based on thin film technology on ceramic and an element built with discrete components, all using the same electronics. It is shown that the operation of all sensor elements with the proposed readout circuit was successful, flow-dependent signals were achieved, and the performance of TMFS in EMST improved. Its heater shows better results compared to the commercial element due to material choice with a smaller temperature coefficient of resistance. In its current state, the TMFS in EMST is suitable to detect flow rates > 20 SLPM. The performance needs to be improved further, since the temperature sensors still differ too much from another. Full article

In high-pressure thermal power systems, corrosion-induced wall thinning in steam pipelines poses a significant threat to operational safety and efficiency. This study investigates the effects of gas–liquid two-phase flow on corrosion-induced wall thinning in pipe bends of high-pressure heaters in power plants, with particular emphasis on the mechanisms of void fraction and inner wall surface roughness. Research reveals that an increased void fraction significantly enhances flow turbulence and centrifugal effects, resulting in elevated pressure and Discrete Phase Model (DPM) concentration at the bend, thereby intensifying erosion phenomena. Simultaneously, the turbulence generated by bubble collapse at the bend promotes the accumulation and detachment of corrosion products, maintaining a cyclic process of erosion and corrosion that accelerates wall thinning. Furthermore, the increased surface roughness of the inner bend wall exacerbates the corrosion process. The rough surface alters local flow characteristics, leading to changes in pressure distribution and DPM concentration accumulation points, subsequently accelerating corrosion progression. Energy-Dispersive Spectroscopy (EDS) and Scanning Electron Microscopy (SEM) analyses reveal changes in the chemical composition and microstructural characteristics of corrosion products. The results indicate that the porous structure of oxide films fails to effectively protect against corrosive media, while bubble impact forces damage the oxide films, exposing fresh metal surfaces and further accelerating the corrosion process. Comprehensive analysis demonstrates that the interaction between void fraction and surface roughness significantly intensifies wall thinning, particularly under conditions of high void fraction and high roughness, where pressure and DPM concentration at the bend may reach extreme values, further increasing corrosion risk. Therefore, optimization of void fraction and surface roughness, along with the application of corrosion-resistant materials and surface treatment technologies, should be considered in pipeline design and operation to mitigate corrosion risks. Full article

This study examines the impact of Au nanoparticles (Au-NPs) on the chemoresistive gas sensing properties as a function of particle size. The sensing material is composed of ultrathin CuO/Cu₂O films, which are fabricated by either thermal deposition technology or spray pyrolysis. These are used on a silicon nitride (Si₃N₄) micro hotplate (µh) chip with Pt electrodes and heaters. The gas sensing material is then functionalised with Au-NP of varying sizes (12, 20, and 40 nm, checked by transmission electron microscopy) using drop coating technology. The finalised sensors are tested by measuring the electrical resistance against various target gases, including carbon monoxide (CO), carbon dioxide (CO₂), and a mixture of hydrocarbons (HC_Mix), in order to evaluate any cross-sensitivity issues. While the sensor response is markedly contingent on the structural surface, our findings indicate that the dimensions of the Au-NPs exert a discernible influence on the sensor’s behaviour in response to varying target gases. The 50 nm thermally evaporated CuO/Cu₂O layers exhibited the highest sensor response of 78% against 2000 ppm CO₂. In order to gain further insight into the surface of the sensors, a scanning electron microscope (SEM) was employed, and to gain information about the composition, Raman spectroscopy was also utilised. Full article

Using multi-power supply units to power large-area electrothermal films can achieve high electrothermal power under low voltage. However, this method may result in poor contact between the electrodes and the electrothermal film, especially for films with large areas and curved surfaces, as well as for power supply units with small electrode spacing. This study found that the relative deviation between the measured value (R_M) and the theoretical value (R_P) of the parallel resistance, ${\displaystyle \frac{R_M-R_P}{R_P}}$, exceeds 12.8% when powering a planar Indium Tin Oxide (ITO) electrothermal film with an area of 5 cm × 5 cm and electrode spacing of less than 0.5 cm using four or more power supply units. This deviation is significantly higher than that observed for power supply units with electrode spacing ≥0.8 cm, where ${\displaystyle \frac{R_M-R_P}{R_P}}$ is 1.4% and 0.3% for spacings of 0.8 cm and 1.1 cm, respectively. By using fine sand, springs, and airbags as power supply pedestals, close contact between the electrodes and the electrothermal film can be achieved for large-area and curved-surface films due to the deformation of the sand, springs, or airbags under the heater’s weight. When an airbag power supply pedestal with twelve power supply units is used to power the bottom of an electrothermal ceramic teacup with a 20 cm² curved ITO transparent electrothermal film, the ${\displaystyle \frac{R_M-R_P}{R_P}}$ is 13.3% and the heating temperature reaches 83.1 °C. Full article

Fiber-shaped electrical heaters with high flexibility and excellent adaptability make an ideal candidate for the application of wearable electronics but still suffer from low strength and poor durability. Herein, an all-in-one Joule-heating fiber capable of outstanding mechanical properties, good heating efficiency, and long-term stability is reported by using polymer-assisted metal deposition to firmly coat Cu nanoparticles on high-performance liquid crystal polymer (LCP) fibers. Taking advantage of LCP, the resultant fibers exhibit a satisfying temperature threshold (up to 200 °C) and immense strength (2.94 GPa). By virtue of dense and continuous Cu film, these fibers show low electrical resistance (5.51 Ω/cm) and an ultrafast response rate (12.6 °C·s⁻¹) at low supplied voltages (0.5–3.5 V). Benefiting from the levodopa/polyethyleneimine interface design, such fibers maintain nearly constant resistance after repeatable bending, folding, and even washing (50 cycles). Based on the above-mentioned merits, a wearable patch with a Joule-heating function is knitted by using as-made fibers to offer therapeutic benefits for human body joints. This work demonstrates prospective potential for enriching the challenging applications of fiber-shaped electrical heating systems. Full article

Graphene/CNT layers were deposited onto platinum electrodes of an interdigitated sensor using radio-frequency magnetron sputtering. The graphene/CNTs were synthesized in an Argon atmosphere at a pressure of (2 × 10⁻²–5 × 10⁻³) mbar, with the substrate maintained at 300 °C either through continuous heating with an electronically controlled heater or by applying a −200 V bias using a direct current power supply throughout the deposition process. The study compares the surface morphology, carbon atom arrangement within the layer volumes, and electrical properties of the films as influenced by the different methods of substrate heating. X-ray diffraction and Raman spectroscopy confirmed the formation of CNTs within the graphene matrix. Additionally, scanning electron microscopy revealed that the carbon nanotubes are aligned and organized into cluster-like structure. The graphene/CNT layers produced at higher pressures present exponential I–V characteristics that ascertain the semiconducting character of the layers and their suitability for applications in gas sensing. Full article

Transparent thin-film heaters have sparked great interest in both the scientific and industrial sectors due to their critical role in various technologies, including smart windows, displays, actuators, and sensors. In this review, we summarize the structural design, fabrication methods, properties, and materials used in thin-film heaters. We also discuss methods to improve their efficiency and recent advancements in the field, and provide insights into the market size, growth, and future outlook for thin-film heaters. Full article

A four-tether silicon microthermocycler for point-of-care PCR analytical systems is proposed. Substituting the commonly employed platinum with titanium in the fabrication of thin film resistance temperature detectors and heaters enabled the realization of a smaller device without compromising temperature accuracy or increasing heater lead power losses. The device was extensively analyzed through analytical modeling and FEM numerical simulations using a 3-D thermo-mechanical simulation model in COMSOL. Numerical simulations revealed that the four-tether design provides a 460% improvement in mechanical strength and a 57% reduction in the thermal time constant compared with a similar three-tether design, with a trade-off of a 22% increase in heat losses. Detailed structural and thermal analyses of crucial design parameters guided the optimization of the final geometry, leading to the successful fabrication of prototypes. It was shown that the current of 60 mA was sufficient to heat the fabricated solid and hollow silicon structure to 132 °C and 134 °C in 10 s for an applied heater power of 510 mW and 525 mW, respectively. Full article

Electrothermal actuators are highly advantageous for microelectromechanical systems (MEMS) due to their capability to generate significant force and large displacements. Despite these benefits, their application in reconfigurable conduction line switches is limited, particularly when employing commercial processes. In DC MEMS switches, electrothermal actuators require electrical insulation between the biasing voltage and the transmission line to prevent interference and maintain the integrity of the switch. This work presents a chevron-type electrothermal actuator utilizing a stack of $\mathrm{S}\mathrm{i}{\mathrm{O}}_2/$ Al thin films on a silicon (Si) structural layer beam to create a DC MEMS switch. The design leverages a thin film Al heater to drive the actuator while the $\mathrm{S}\mathrm{i}{\mathrm{O}}_2$ layer provides electrical insulation, suppressing crosstalk with the Si layer. The electrical contact resistance of a Si-to-Si interface was evaluated by applying a controlled current and measuring the resultant voltage. A low contact resistance of 150 Ω was achieved when an initial contact gap of 2.52 μm was closed using an actuator with an actuation voltage of 1.2 V and a current of 205 mA, with a switching speed of less than 5 ms. Factors such as the contact force, the temperature, and the residual device layer etching angle significantly impact the Si-to-Si contact resistance and the switch’s longevity. The switch withstands a breakdown voltage up to 350 V at its terminal contacts. Thus, it will be robust to self-actuation caused by unwanted voltage contributions, making it suitable for high-voltage and harsh environment applications. Full article

In this paper, the impact of Lorentz forces and temperature on the natural frequencies of a piezoresistive sensor composed of two microcantilevers with integrated U-shaped thin-film aluminum heaters are investigated. Two types of experiments were performed. In the first, the sensor was placed in a magnetic field so that the current flowing in the heater, in addition to raising the temperature, produced Lorentz forces, inducing normal stresses in the plane of one of the microcantilevers. In the second, which were conducted without magnetic fields, only the temperature variation of the natural frequency was left. In processing of the results, the thermal variations were subtracted from the variations due to both Lorentz forces and temperature in the natural frequency, resulting in the influence of the Lorentz forces only. Theoretical relations for the Lorentz frequency offsets were derived. An indirect method of estimating the natural frequency of one of the cantilevers, through a particular cusp point in the amplitude–frequency response of the sensor, was used in the investigations. The findings show that for thin microcantilevers with silicon masses on the order of 4 × 10⁻⁷ g and currents of 25 µA, thermal eigenfrequency variations are dominant. The results may have applications in the design of similar microsensors with vibrational action. Full article

The optimization of the process of polymer film orientational drawing using the local heater was investigated. One of the problems with this technology is that the strength of the resulting fibers differs significantly from the theoretical estimates. It is assumed that one of the reasons is related to the peculiarity of this technology, when at the point of drawing the film is heated only on one side, which creates a temperature difference between the sides of the film in contact with the heater and the non-contact sides of the film in the air. Estimates show that even a small temperature difference of just 1 °C between these surfaces leads to a significant difference in the rate of plastic deformation of the corresponding near-surface layers. As a consequence, during hardening, in the stretching region, tensile stress is concentrated on the “cold” side of the film, and this effect can presumably lead to the generation of more defects overthere. It has been suggested that defects arising during first stage of hardening, namely, neck formation, can serve as a trigger for the formation of defects such as kink bands on the “cold” side with further orientational strengthening due to plastic deformation of the resulting fibrillar structure, at the boundaries of which microcracks are formed, leading to rupture of the oriented sample. The numerical calculation of heat propagation due to heat conduction in the film from the local surface of the heater is carried out and the temperature distribution along the thickness and width of the film during drawing is found. The temperature difference in the heated layer of the film between the contact and non-contact sides with the heater was calculated depending on the thickness of the film and the speed of its movement along the heater. It was found that the most homogeneous temperature distribution over the film thickness, which is required, by default, for the synchronous transformation of the unoriented initial folded lamellar structure into a fibrillar structure, is observed only for films with a thickness of less than 50 μm. The calculation allows us to scientifically justify the choice of orientation drawing speed and optimal thickness of the oriented polymer film, which is extremely important, for example, for obtaining super-strong and high-modulus UHMWPE filaments used in products for various purposes: from body armor to sports equipment and bioimplants, Full article

This study analyzes the effect of the temperature coefficient of electric resistance on the thermal performance of a film heater for satellite applications. A heating element in the film heater was fabricated using silver paste and screen-printing technology. The temperature distributions of the film heater were numerically simulated on the basis of the heat transfer equation. The temperature coefficient of resistance was evaluated by measuring the film-heater temperature at various voltages using a forward-looking infrared (FLIR) camera. The results showed that the electric resistance linearly increased with a temperature variation. By considering the temperature coefficient of electric resistance, the error of numerical simulation decreased from 22.5% to 10%. The voltage required to reach the maximum allowable temperature at a given sink temperature was higher than the design voltage when the temperature coefficient was not considered. This indicated that greater power would be required to operate the film heater in real satellite applications. Full article

Soft transportation devices with high flexibility, good stability, and quick controllability have attracted increasing attention. However, a smart soft transportation device with tactile perception and a non-contact actuating mode remains a challenge. This work reports a magnetic soft pipeline (MSP) composed of sensor film, a magnetorheological elastomer (MRE) cavity pipeline, and heater film, which can not only respond well to tactile compression stimuli but also be transported by magnetic actuation. Notably, the sensor film was integrated on the upper surface of an MRE pipeline, and the relative resistance change (∆R/R₀) of the MSP was maintained at 55.8% under 2.2 mm compression displacement during 4000 loading cycles. Moreover, the heater film was integrated on the lower surface of the MRE pipeline, which endows the MSP with an electrothermal heating characteristic. The temperature of the MSP can be increased from 26.7 °C to 38.1 °C within 1 min under 0.6 V. Furthermore, the MSP was attracted and deformed under the magnetic field, and the ∆R/R₀ of the MSP reached 69.1% under application of a 165 mT magnetic field density. Benefiting from the excellent perception and magnetic deformation performances, the magnetic actuate transportation of the MSP with self-sensing was successfully achieved. This multi-functional soft pipeline integrated with in situ self-sensing, electrothermal heating, and non-contact magnetic actuating transportation performance possess high potential in smart flexible electronic devices. Full article

A novel non-isothermal glass hot embossing system utilizes a silicon mold core coated with a three-dimensional carbide-bonded graphene (CBG) coating, which acts as a thin-film resistance heater. The temperature of the system significantly influences the electrical conductivity properties of silicon with a CBG coating. Through simulations and experiments, it has been established that the electrical conductivity of silicon with a CBG coating gradually increases at lower temperatures and rapidly rises as the temperature further increases. The CBG coating predominantly affects electrical conductivity until 400 °C, after which silicon becomes the dominant factor. Furthermore, the dimensions of CBG-coated silicon and the reduction of CBG coating also affect the rate and outcome of conductivity changes. These findings provide valuable insights for detecting CBG-coated silicon during the embossing process, improving efficiency, and predicting the mold core’s service life, thus enhancing the accuracy of optical lens production. Full article