Resistive heaters and uses thereof

Abstract

The present invention features a metallic resistive heater and uses thereof. The resistive heater includes a metallic component that is electrically conductive (i.e., has low resistivity) and an oxide, nitride, carbide, and/or boride derivative of the metallic component that is electrically insulating (i.e., has high resistivity). The resistivity is controlled in part by controlling the amount of oxide, nitride, carbide, and boride formation during the deposition of the metallic component and the derivative.

1 - 47 . (canceled)  
   
   
       48 . A method of drying paper during manufacturing comprising the steps of: 
 a) providing paper comprising a water content of greater than about 5% and one or more cylindrical rollers, each comprising an outer surface, an inner surface surrounding a hollow core, and a resistive heater comprising a resistive layer coupled to a power source, said resistive layer comprising a metallic component and one or more oxide, nitride, carbide, and/or boride derivatives of said metallic component, wherein said resistive layer has a resistivity of 0.0001 to 1.0 Ω·cm, and wherein application of current from said power supply to said resistive layer results in production of heat by said resistive layer, wherein said resistive heater is disposed on said outer surface or said inner surface;    b) heating said roller with said resistive heater; and    c) contacting said paper with said roller for a time suitable for drying said paper to a water content of less than about 5%.    
   
   
       49 - 50 . (canceled)  
   
   
       51 . A method of drying paper during manufacturing, the method comprising the steps of: 
 providing paper comprising a water content of greater than about 5%;    providing at least one cylindrical roller, each cylindrical roller comprising, 
 an outer surface,  
 an inner surface surrounding a hollow core, and  
 a resistive heater coating comprising a resistive layer, where the resistive layer is coupled to a power source, the resistive layer comprising a metallic component and one or more oxide, nitride, carbide, and/or boride derivatives of the metallic component, wherein the resistive layer has a resistivity of 0.0001 to 1.0 Ohm-cm, and wherein application of current from the power supply to the resistive layer results in production of heat by the resistive layer, and wherein the resistive heater coating is disposed on the cylindrical roller;  
   heating the cylindrical roller with the resistive heater; and    contacting the paper with the roller for a time suitable for drying the paper to a water content of less than about 5%.    
   
   
       52 . The method of  claim 51 , wherein the at least one cylindrical roller further comprises at least two cylindrical rollers and wherein the step of contacting the paper with the roller further comprises the step of contacting the paper on each of two opposing sides of the paper with the at least two cylindrical rollers.  
   
   
       53 . The method of  claim 51 , wherein, prior to the step of contacting the paper with the roller, the paper comprises a water content of about 30%.  
   
   
       54 . The method of  claim 51 , wherein the resistive heater coating is disposed on the outer surface of the cylindrical roller.  
   
   
       55 . The method of  claim 51 , wherein the resistive heater coating is disposed on the inner surface of the cylindrical roller.  
   
   
       56 . The method of  claim 51 , wherein the at least one cylindrical roller further comprises two ends and a middle portion, and wherein the step of heating the cylindrical roller further comprises heating the two ends of the cylindrical roller to a greater temperature than the middle portion of the cylindrical roller.  
   
   
       57 . The method of  claim 51 , further comprising the step of applying an anticorrosive coating to the cylindrical roller.  
   
   
       58 . The method of  claim 51 , further comprising the step of emitting heat in a selected pattern from the resistive layer.  
   
   
       59 . The method of  claim 51 , further comprising the step of heating the at least one cylindrical roller unevenly.  
   
   
       60 . A method of drying paper during manufacturing, the method comprising the steps of: 
 applying a current through a resistive layer disposed on at least one cylindrical roller;    heating the at least one cylindrical roller with the resistive layer; and    contacting paper having at least approximately 5% water content with the heated at least one cylindrical roller.    
   
   
       61 . The method of  claim 60 , wherein the at least one cylindrical roller further comprises two ends and a middle portion, and wherein the step of heating the cylindrical roller further comprises the step of heating the two ends of the cylindrical roller to a greater temperature than the middle portion of the cylindrical roller.  
   
   
       62 . The method of  claim 60 , further comprising the step of applying an anticorrosive coating to the cylindrical roller.  
   
   
       63 . The method of  claim 60 , further comprising the step of controlling the heating of the at least one cylindrical roller.  
   
   
       64 . The method of  claim 60 , further comprising the step of heating the at least one cylindrical roller unevenly.  
   
   
       65 . The method of  claim 60 , further comprising the step of emitting heat in a selected pattern from the resistive layer.  
   
   
       66 . The method of  claim 60 , wherein the resistive layer is disposed along an inner surface of the at least one cylindrical roller.