Heating device, applications therefore, an ohmically resistive coating, a method of depositing the coating using cold spray and a blend of particles for use therein
A heating device may include a substrate and a heating element disposed on a surface of the substrate. The heating element may include an ohmically resistive coating having a layer thickness of 2 to 300 microns. The ohmically resistive coating may include at least 30% by weight of at least one ductile or malleable metal and a plurality of electrically resistive particles. The ohmically resistive coating may be deposited via the at least one of the cold spray and the solid state deposition performed at a temperature below at least one of a melting temperature and a partially softening temperature of the at least one ductile or malleable metal. The ohmically resistive coating may exhibit less heterogeneity and porosity than a thermally sprayed coating, may have a density of 90% or greater, and may have a porosity of 10% or less.
1. A heating device, comprising:
a substrate with a surface; and
a heating element disposed on the surface, the heating element including an ohmically resistive coating deposited on the surface of the substrate via at least one of a cold spray and a solid state deposition, the ohmically resistive coating having a layer thickness of 2 to 300 microns and including:
at least 30% by weight of at least one ductile or malleable metal selected from a group including: copper, aluminium, zinc, and manganese; and
a plurality of electrically resistive particles that include at least one of compounds and salts of at least one of a metal and a metalloid;
wherein the at least one ductile or malleable metal bonds the plurality of electrically resistive particles to the surface of the substrate to form the ohmically resistive coating;
wherein the ohmically resistive coating is formed via the at least one of the cold spray and the solid state deposition performed at a temperature below at least one of a melting temperature and a partially softening temperature of the at least one ductile or malleable metal;
wherein the ohmically resistive coating exhibits less heterogeneity and porosity than a thermally sprayed coating, has a density of 90% or greater, and has a porosity of 10% or less;
wherein the plurality of electrically resistive particles are disposed in the at least one ductile or malleable metal;
wherein at least a pair of electrical contacts are structured and arranged to connect to a power supply; and
wherein the power supply includes at least one of an AC power supply and a DC power supply.
2. The heating device as claimed in claim 1 , further comprising a plurality of heating elements, including the heating element, that each share a common feed terminal and that each have an independent return terminal.
3. The heating device as claimed in claim 1 , wherein the power supply is a mains operated power supply.
4. The heating device as claimed in claim 1 , wherein the power supply is a low voltage supply operating at least one of:
in a range of 1 to 110 Volts; and
below 30 Volts.
5. The heating device as claimed in claim 1 , wherein the surface includes a dielectric barrier material.
6. The heating device as claimed in claim 5 , wherein the dielectric barrier material is a ceramic.
7. The heating device as claimed in claim 1 , wherein the substrate includes a sheet material.
8. The heating device as claimed in claim 7 , wherein the sheet material includes at least one of:
an architectural panel;
a steel core and a ceramic surface;
a glass sheet; and
a mirrored glass sheet.
9. The heating device as claimed in claim 1 , wherein the surface has a heated surface area of 150 cm 2 to 20,000 cm 2 .
10. The heating device as claimed in claim 1 , wherein the heating element is a self-regulating resistance heating element.
11. A vehicle, comprising the heating device as claimed in claim 1 .
12. A building, comprising the heating device as claimed in claim 1 .
13. An ohmically resistive coating, comprising a layer deposited on a surface of a substrate via at least one of cold spray and solid state deposition, the layer having a thickness of 2 to 300 microns and includes:
at least 30% by weight of at least one ductile or malleable metal selected from a group including: copper, aluminium, zinc, and manganese;
a plurality of electrically resistive particles that include at least one of compounds and salts of at least one of a metal and a metalloid;
wherein the at least one ductile or malleable metal bonds the plurality of electrically resistive particles to the surface of the substrate to form the ohmically resistive coating;
wherein the ohmically resistive coating is formed via the at least one of the cold spray and the solid state deposition performed at a temperature below at least one of a melting temperature and a partially softening temperature of the at least one ductile or malleable metal;
wherein the ohmically resistive coating exhibits less heterogeneity and porosity than a thermally sprayed coating, has a density of 90% or greater, and has a porosity of 10% or less;
wherein the plurality of electrically resistive particles are embedded in the at least one ductile or malleable metal.
14. The ohmically resistive coating as claimed in claim 13 , wherein the thickness of the layer is 20 to 70 microns.
15. The ohmically resistive coating as claimed in claim 13 , wherein the layer covers at least 10%, by area, of the surface of the substrate.
16. The ohmically resistive coating as claimed in claim 15 , wherein the layer covers at least 50%, by area, of the surface of the substrate.
17. The ohmically resistive coating as claimed in claim 13 , wherein the layer is deposited as at least one of a single track and a plurality of tracks.
18. A method of forming an ohmically resistive coating, comprising:
providing a blend including:
at least 30% by weight of at least one ductile or malleable metal selected from a group including: copper, aluminium, zinc, and manganese; and
a plurality of electrically resistive particles including at least one of a metal and a metalloid together with compounds or salts thereof;
feeding the blend into at least one of a cold spray apparatus and a solid-state deposition apparatus; and
adhering the blend to a surface of a substrate via depositing a plurality of blend particles of the blend with a heated, compressed, supersonic gas jet;
wherein depositing the plurality of blend particles with the gas jet includes accelerating the plurality of blend particles through a nozzle, at a temperature that is below at least one of a melting temperature and a partially softening temperature of the at least one ductile or malleable metal and at a pressure, to the surface of the substrate which is positioned a distance from the nozzle such that the plurality of blend particles adhere to the surface and form the ohmically resistive coating thereon;
wherein the ohmically resistive coating exhibits less heterogeneity and porosity than a thermally sprayed coating, has a density of 90% or greater, and has a porosity of 10% or less; and
wherein the plurality of electrically resistive particles are embedded in the at least one ductile or malleable metal.
19. The method as claimed in claim 18 , wherein the temperature is 600° C. or less.
20. The method as claimed in claim 18 , wherein the pressure is 1 to 10 Atm.
21. The method as claimed in claim 18 , wherein the method is conducted absent of a vacuum.
22. The method as claimed in claim 18 , wherein the distance is at least one of:
less than 1 m; and
1 to 30 cm.
23. The method as claimed in claim 18 , wherein the plurality of particles have a mean particle size of at least one of:
0.1 to 150 microns; and
15 to 35 microns.
24. The method as claimed in claim 18 , wherein the gas is at least one of air, oxygen, nitrogen, carbon dioxide, argon, and neon.
25. A method of heating a space, comprising supplying power to the heating device claimed in claim 1 .
26. The method as claimed in claim 25 , further comprising heating the heating device to >90° C. in under 5 minutes.
27. The method as claimed in claim 25 , wherein heat is generated primarily in the form of infra-red radiant heat energy.
28. The heating device as claimed in claim 1 , wherein:
the compounds of the at least one of the metal and the metalloid include at least one of an oxide, a carbide, a nitride, and a boride; and
the salts of the at least one of the metal and the metalloid include at least one of a silicide and a di-silicide.
29. The heating device as claimed in claim 1 , wherein at least one of:
the temperature is 400° C. or less;
the at least one ductile or malleable metal is zinc; and
the layer thickness of the ohmically resistive coating is 20 to 70 microns.
30. The ohmically resistive coating as claimed in claim 13 , wherein the temperature is 600° C. or less.
31. The ohmically resistive coating as claimed in claim 13 , wherein the temperature is 400° C. or less.
32. The ohmically resistive coating as claimed in claim 13 , wherein the at least one ductile or malleable metal is zinc.
33. The method as claimed in claim 18 , wherein the at least one ductile or malleable metal is zinc.
34. The method as claimed in claim 18 , wherein the ohmically resistive coating has a thickness of 20 to 70 microns.
35. An ohmically resistive coating, comprising a layer deposited on a surface of a substrate via at least one of cold spray and solid state deposition performed at a temperature of 400° C. or less, wherein:
the layer includes:
at least 30% by weight of zinc; and
a plurality of electrically resistive particles that include at least one of compounds and salts of at least one of a metal and a metalloid;
the plurality of electrically resistive particles are embedded in the zinc and the zinc bonds the plurality of electrically resistive particles to the surface of the substrate; and
the layer exhibits less heterogeneity and porosity than a thermally sprayed coating, has a porosity of 10% or less, and has a thickness of 2 to 300 microns.
36. The ohmically resistive coating as claimed in claim 35 , wherein the thickness of the layer is 20 to 70 microns.