CN102161245A - Manufacture method for positive temperature coefficient devices and anti-overheating system for plane heating element - Google Patents

Manufacture method for positive temperature coefficient devices and anti-overheating system for plane heating element Download PDF

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CN102161245A
CN102161245A CN2010101937371A CN201010193737A CN102161245A CN 102161245 A CN102161245 A CN 102161245A CN 2010101937371 A CN2010101937371 A CN 2010101937371A CN 201010193737 A CN201010193737 A CN 201010193737A CN 102161245 A CN102161245 A CN 102161245A
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positive temperature
temperature coefficient
manufacture method
coefficient device
heater
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CN102161245B (en
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康锡焕
金文汉
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UNIPLATEK CO Ltd
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Abstract

The invention discloses a manufacture method for positive temperature coefficient devices and an anti-overheating system for a plane heating element, comprising steps of mixing one or more than two polymer resins, carbon blacks and additives selected from ethylene butyl acrylate monomer copolymer, ethylene vinyl acetate copolymer, and polyoxyethylene, squeezing the mixed composite into a thin-film shape and adhering electrodes to the two sides, and irradiating electron rays to perform crosslinking processing. Then, the plurality of positive temperature coefficients are in a serial connection to be used as anti-overheating sensor cables of a plane heating element controller and are adhered to the surface of the heating element in certain spacing, the positive temperature coefficient anti-overheating sensor cables are in a bending arrangement toward any direction at a position using the plane heating body, therefore, the positive temperature coefficient devices are in a scattering arrangement at any position. When heating phenomenon is generated at the part adhered by positive temperature coefficients and the surrounding area due to abnormal operation, power on of the plane heating body is controlled, thereby improving anti-overheating safety, saving energy, facilitating construction, saving cost and improving durability.

Description

Positive temperature coefficient device manufacture method and plane heater are prevented superheating system
Technical field
The present invention relates to positive temperature coefficient (Positive Temperature Coefficient, PTC) device making method and utilize the anti-superheating system of plane heater of above-mentioned positive temperature coefficient device, a plurality of positive temperature coefficient devices of connecting are as the anti-overheat sensor of plane heater controller, thereby when overheated (or accumulation of heat) phenomenon takes place, the energising of control plane heater is to improve the security of plane heater.
Background technology
Up to the present, the heating of widely used ground and other various heating installations are most of for using the heating installation of fossil fuels such as oil, natural gas, but the serious problems of the problem of environmental pollution that pernicious gas caused that is produced during because of imperfect combustion and the exhaustion of fossil fuel, people are more and more higher to the care of the heating installation that utilizes alternative energy source, and, use more now thereby develop the electric heating appliance that substitutes fossil fuel and make electricity consumption to its research and development that continues.But, at the electricity consumption adstante febre, up to the present main the employing by the local heat of resistive element, electric arc, eddy-current heating etc. or the mode of heating of one dimension line, heating heat is concentrated and is distributed in around the thermal source, therefore, consider from the efficiency aspect, need the even heating of the two dimensional surface of broad, thereby carried out the research of new electric heat source and develop the plane heater.
The plane heater is to be film shape, to connect power supply by insert thin electrode at its two ends, to pass through the material of the resistance components heating that the electric current supplied and material self possessed, it is because of having outstanding flexibility, can on two-dimensional plane, evenly generate heat, and alternative fossil energy, obtain the effect of economy, environmental protection, thereby, be used for various forms of heating systems (bottom surface, wall, roof etc.) and industrial heaters as heating installation thermal source of new generation.
In the temperature regulation mechanism of plane heating, the most a kind of mode of extensive employing is the electric control mode by temperature sensor.It is by on the heater surface temperature sensor being set, thereby is the mode of standard adjustment heating with the temperature that is shown in sensor.When the plane heater is used for the ground heating system, the temperature control method to heater of extensive employing is: temperature sensor (thermistor, bimetallic etc.) is attached to the heater surface and measures the heater temperature, thereby be that standard is controlled with the temperature that sets.
The problem of this mode maximum is, is the temperature of standard adjustment whole system with the heating temp value around the sensor.If certain temperature can be kept in whole surface, this mode can not become problem, but if certain the part accumulation of heat (thermal-arrest) except that sensor site then can damage finishing material and product, therefore, need cause user's attention especially.For example, the phenomenon that causes finishing material damage, reduction properties of product and breakage because of accumulation of heat (thermal-arrest) is arranged, in daily life, if quilt, ground cushion and having can stop to the object Long contact time temperature control of the character of air heat radiation with the part outside the sensor site, then than the control temperature, its temperature will sharply rise, and if continue to keep such state, then will cause finishing material damage, reduction properties of product and damaged phenomenon.
Promptly, because by only measuring the temperature control heater of temperature sensor present position, therefore, according to external insulation degree and environment temperature, the remarkable temperature difference that may cause the part of contiguous temperature sensor and the part far away of being separated by, but can not control the heat that heater produces, thereby need cause user's attention especially.That is, if there not being the part of temperature sensor, place the object that quilt, ground cushion etc. have the character that can stop heat radiation for a long time, then than controlling temperature on every side, its temperature will sharply rise, thereby causes reducing the phenomenon of properties of product or damage finishing material.
For addressing the above problem, preferably,, rise to the above superheating phenomenon of normal serviceability temperature thereby prevent temperature by in the heater scope of whole plane, carrying out temperature treatment.
The mode of temperature detection by all kinds of means of prior art is subjected to the restriction of system development and construction.In temperature detection mode by all kinds of means, be the large-area temperature not a duck soup of standard adjustment with the data value that receives from each channel.If it is unusual that a sensor in a plurality of temperature sensors takes place, will exert an influence to whole system, therefore, be difficult to find best heating condition, actuality is relatively poor.In addition,, therefore, be difficult to installation, and operating expenses is also higher relatively because of the complex structure of ground heating system.
In addition, PTC (Positive Temperature Coefficient, positive temperature coefficient) heater (positive temperature coefficient heater) is based on the narrower microheater parts of electrode spacing, heating is used for the very construction of small size with product, but its expense is higher relatively, and most of product is the low-voltage product.Its reason is, applies forceful electric power repeatedly if make the heating of positive temperature coefficient heater and presses (more than the AC100V), and then because of the deterioration of positive temperature coefficient heater and the repeatability restriction of positive temperature coefficient device, product is impaired easily.
Summary of the invention
The objective of the invention is to overcome the deficiency of prior art, and provide a kind of plane heater to prevent superheating system and operation method thereof, it is made and is suitable for the positive temperature coefficient device of making anti-overheat sensor, and a plurality of positive temperature coefficient device series connection also are attached to the heater surface at regular intervals, thereby in the heater heating system of plane, prevent part overheated (or accumulation of heat) phenomenon, and have IMAGE and installation, improve security.
Below, the present invention is described in detail.
In making positive temperature coefficient device process of the present invention, the crystal type polyolefin resin can use the disclosed all types of the industry, and preferably, use one or more resins of from ethylene butyl acrylate (ethylene butyl acrylate) copolymer, ethylene vinyl acetate (ethylene vinylacetate) copolymer, polyethylene glycol oxide (polyethylene oxide), selecting.Particularly, preferably, use the macromolecule resin that is applicable to 40~120 ℃ of optimum temperatures as the anti-overheat sensor of plane heater, with in narrow temperature range to temperature increase make a response, thereby increase the resistance of synthetic, and use amount is 20~70 weight portions.If the content of macromolecule resin is lower than 20 weight portions, then the mixing of positive temperature coefficient device and moulding are difficult, and if surpass 70 weight portions, then because of reducing the content of electric conductivity filler relatively, therefore, the conductance of positive temperature coefficient is higher under the normal temperature condition.
In addition, preferably, be used for electric conductivity filler of the present invention and use one or more the carbon black of selecting from average grain diameter 70~300nm.Alternative condition with carbon black of outstanding ptc characteristics is, particle size is big, but relative surface area is little, and positive temperature coefficient intensity at this moment (PTC intensity) is big.If average grain diameter is less than 70nm, though then the conductance under the normal temperature state is good, the positive temperature coefficient undercapacity, and if greater than 300nm, though then positive temperature coefficient intensity is big, the conductance under the Yin Changwen state is little, and preferably, its use amount is 30~80 weight portions.If the content of carbon black is less than 30 weight portions, the conductance deficiency the normal temperature state under then, and if greater than 80 weight portions, then the content because of macromolecule resin reduces relatively, thus mix and moulding difficulty.
Above-mentioned additive can use one or more the mixture of selecting from antioxidant, UV stabilizing agent and crosslinking agent, and so long as normally used in the corresponding field, then has no particular limits.Particularly, antioxidant can use Irganox and Phosphorus antioxidant Ultranox, the Richnox etc. of carbolic acid class; The UV stabilizing agent can use Tinuvin, Chimassob etc.; And crosslinking agent can use Dicumyl peroxide etc.Above-mentioned additive can use one or more the mixture of selecting from antioxidant, UV stabilizing agent and crosslinking agent.And preferably, use amount is 0.1~3 weight portion, if use amount is greater than 3 weight portions, and the conductance height of positive temperature coefficient device under the normal temperature state then, and positive temperature coefficient intensity is little.
Preferably, the mixing temperature of positive temperature coefficient device of the present invention is to be higher than the temperature of employed macromolecule resin fusion point more than 20 ℃.If mixing temperature is lower than fusion point, then mix not exclusively between electric conductivity filler and the macromolecule resin, and, then will cause the caused characteristic variations of thermal decomposition of macromolecule resin if temperature is too high.Mixing arrangement can use disclosed any device.
Preferably, in the melt temperature scope of macromolecule resin, well-mixed electric conductivity synthetic in the said process is formed electrode (metallic plate) on the two sides, and be made into the positive temperature coefficient device that thickness is the film shape of 0.2~3mm, if thickness less than 0.2mm, then is difficult to moulding, and if surpass 3mm, then because of electrode spacing is bigger, thereby normal temperature resistance is higher.At this moment, employed metallic plate is that resistance is low, is difficult for the metallic plate (copper, aluminium, stainless steel etc.) of oxidation, so long as disclosed getting final product.
Then, finish the crosslinked operation that changes the inner bonding state of macromolecule resin, to increase the intensity and the durability of resin, and at the above temperature removal of fusion point negative temperature coefficient (Negative Temperature Coefficient, NTC) phenomenon, thus make the positive temperature coefficient phenomenon show more stablely.Above-mentioned crosslinked operation is to shine with electron ray, in order to formation physical property cross-linked structure in macromolecule resin, thereby more than fusion point, removes the negative temperature coefficient phenomenon by the flocculation again of carbon black.Preferably, the electron ray exposure is 5~320keV, if be lower than 5keV, then because of the crosslinked deficiency of macromolecule resin, thereby reduce the characteristic repeatedly of positive temperature coefficient, and if be higher than 320keV, then because of the thermal decomposition of macromolecule resin etc., reduce the intensity of positive temperature coefficient.
In addition, can as required after electron ray is crosslinked or after the anti-overheat sensor cable of making, increase the step of anneal (Annealing).Positive temperature coefficient device is in its manufacture process, be subjected to various forms of thermal shocks, and in order to ensure the positive temperature coefficient property of final positive temperature coefficient device, can annealed operation further improve ptc characteristics, promptly keep certain hour once, to relax potential thermal stress in the melt temperature of macromolecule resin.
The present invention can be manufactured in 40~120 ℃ that are suitable for the anti-overheat sensor of plane heater and show ptc characteristics, and possesses outstanding normal temperature resistance, positive temperature coefficient intensity and the positive temperature coefficient positive temperature coefficient device of characteristic repeatedly, and, provide the plane heater that has improved the security that prevents plane heater overheated (or accumulation of heat) phenomenon anti-superheating system by with the anti-overheat sensor of above-mentioned positive temperature coefficient device as the plane heater.
Description of drawings
Fig. 1 is the performance diagram according to the positive temperature coefficient device of electron ray exposure of first embodiment;
Fig. 2 is the performance diagram according to the positive temperature coefficient device of electron ray exposure of second embodiment;
Fig. 3 is the performance diagram according to the positive temperature coefficient device of electron ray exposure of the 3rd embodiment;
Fig. 4 is the performance diagram according to the positive temperature coefficient device of electron ray exposure of the 4th embodiment;
Fig. 5 is the performance diagram according to the positive temperature coefficient device of electron ray exposure of the 5th embodiment;
Fig. 6 is the performance diagram according to the positive temperature coefficient device of electron ray exposure of the 6th embodiment;
Fig. 7 is the performance diagram according to the positive temperature coefficient device of electron ray exposure of the 7th embodiment;
Fig. 8 is the performance diagram according to the positive temperature coefficient device of electron ray exposure of the 8th embodiment;
Fig. 9 is the performance diagram of the preceding positive temperature coefficient device of annealing of the 7th embodiment;
Figure 10 is the performance diagram of annealing (annealing is 12 hours in 60 ℃) the back positive temperature coefficient device of the 7th embodiment;
Figure 11 shines electron ray positive temperature coefficient afterwards performance diagram repeatedly with 20keV in the 3rd embodiment;
Figure 12 shines electron ray positive temperature coefficient afterwards performance diagram repeatedly with 20keV in the 7th embodiment;
Figure 13 is the general view that utilizes the anti-overheat sensor cable of positive temperature coefficient device;
Figure 14 is for being provided with the schematic diagram of the anti-overheat sensor cable of positive temperature coefficient on the heater of plane, it is single controlling channel circuit skeleton diagram;
Figure 15 is for being provided with the schematic diagram of the anti-overheat sensor cable of positive temperature coefficient on the heater of plane, it is a control circuit skeleton diagram by all kinds of means;
Figure 16 is the structure chart of automatic temperature regulator one embodiment of the present invention;
Figure 17 is the flow chart of automatic temperature-adjusting control method one embodiment of the present invention;
Figure 18 is the heating system accumulation of heat phenomenon curve map according to the prior art automatic temperature regulator;
Figure 19 is according to the heating system accumulation of heat phenomenon curve map of utilization according to the anti-superheating system of plane heater of the anti-overheat sensor cable of the positive temperature coefficient device of the embodiment of the invention 7.
The specific embodiment
Below, the present invention is described in detail in conjunction with the embodiments, but scope of the present invention is not subjected to the restriction of following embodiment.
Content shown in the following table 1 and condition are made positive temperature coefficient device.
[table 1]
Resin 1: ethylene butyl acrylate copolymer
Resin 2: ethylene vinyl acetate copolymer
Resin 3: ethylene vinyl acetate copolymer
Resin 4: polyethylene glycol oxide
CB1: particle size 300nm
CB2: particle size 70nm
Antioxidant: Richnox
UV stabilizing agent: Chimassob
Crosslinking agent: Dicumyl peroxide
The characteristic of the positive temperature coefficient device that manufacturing forms is as follows: Fig. 1 to Fig. 8 is the rerum natura curve map according to the positive temperature coefficient device of electron ray cross-link intensity.To shown in Figure 8, as a whole, under the above condition of 20keV, stop moving of carbon black as Fig. 1 because of in positive temperature coefficient device, forming tridimensional network, the activity of stablizing positive temperature coefficient, thus the negative temperature coefficient phenomenon does not appear.
Fig. 9 and Figure 10 are the ptc characteristics change curve according to annealing.For adhering to suffered thermal shock pressure of when lead-in wire,, implement 12 hours annealing in the melt temperature of matrix resin once.
Fig. 9 and Figure 10 represent the characteristic variations result according to the positive temperature coefficient device of annealing.As shown in the figure, the variation of initial stage normal temperature resistance is little, but positive temperature coefficient resistor and positive temperature coefficient intensity increase more than 100 times relatively.
Then, the characteristic repeatedly to positive temperature coefficient device experimentizes.Test repeatedly with change of temperature test (30 ℃, 10 minutes
Figure GSA00000133398800091
90 ℃, 10 minutes, 100 times) mode implement, and as Figure 11 and shown in Figure 12, in 60 ℃ and 100 ℃ of positive temperature coefficient running temperatures, positive temperature coefficient intensity continues to keep 10 4More than.
As shown in figure 13, the anti-overheat sensor cable that utilizes positive temperature coefficient device of the present invention is made by utilizing welding or connector a plurality of positive temperature coefficient devices of connecting at regular intervals.For airtight protection from physical impact and moisture, above-mentioned positive temperature coefficient device utilizes wrapped with insulation.
Above-mentioned insulating materials mixes one or more resins of selecting and is made from adhesives such as epoxy resin, polyurethane resin, silicones, mylar, melmac or ethylene vinyl acetate class, and preferably, select for use to possess outstanding resistance to impact, to resist physical impact and to prevent the resin that moisture is wet thoroughly.
Anti-overheat sensor cable is several cable forms to hundreds of positive temperature coefficient devices of series connection, and as Figure 14 and shown in Figure 15, can be at the position of using the plane heater with the random length cut-out and to any direction bending, and in a zigzag being attached to heater front, plane, thereby disperse to be provided with positive temperature coefficient device at an arbitrary position.There are differences according to different environments for use, but preferably, unit are (m 2) on be provided with at least more than one.
Heater anti-superheating system in plane of the present invention relates to automatic temperature regulator and operation method thereof, and wherein, automatic temperature regulator comprises: temperature sensor generates heat to uniform temperature heater; Anti-overheat sensor cable prevents overheated and utilizes positive temperature coefficient device to be made during operation exception; Control part is according to the signal controlling plane heating unit power from the sensor (temperature sensor, anti-overheat sensor cable) input.
Figure 16 comprises I/O portion, microcomputer, heater control part, positive temperature coefficient sensor measurement portion for the structure chart of automatic temperature regulator of the present invention.Input part is accepted design temperature and is sent to microcomputer from the user, and efferent is accepted current heating temp and is shown to the user from microcomputer.Basic operation order is as follows: connect the automatic temperature regulator power supply and imported after the design temperature by the user, microcomputer is known heating temp by temperature sensor, if heating temp is lower than design temperature, then apply power supply by the control control part, and if heating temp is higher than design temperature, then cut off the electricity supply, with the control heater by the control control part.
Positive temperature coefficient sensor measurement portion prevents the overheat sensor cable by regularly detecting, and when causing superheating phenomenon because of misoperation, control heater control part.Figure 17 represents to illustrate the flow process of an embodiment of above-mentioned automatic temperature-adjusting control method.
As mentioned above, the present invention utilizes the anti-superheating system of the plane heater of positive temperature coefficient device, its maximum application area depends on the capacity of automatic temperature regulation device, therefore, according to construction area adopt by a channel constitute but canalization (Figure 14) and certain zone is divided into the anti-by all kinds of means superheating system (Figure 15) of a channel, and can be formed in certain part and detect and cut off electric current when overheated rapidly, control the circuit of corresponding channel superheating phenomenon with moment, thereby under the prerequisite of exerting an influence for whole heating system, only overheated certain zone is controlled.
Realized utilizing the ground heating system of plane heater, on floor area 2*2M, with operate power 850W, carry out after the installation as Figure 14, weight is about 2Kg, size is positioned over construction surface for the heat insulation material (blanket) about 1*1.5M, implements artificial accumulation of heat phenomenon, and the present invention prevents superheating system with checking.
Figure 18 is the situation of adhering to the general automatic temperature regulator of prior art, and it is a curve map of verifying the accumulation of heat phenomenon at the position of not adhering to temperature sensor; And Figure 19 is as temperature sensor and the anti-overheat sensor cable of the present invention, unit are (m 2) situation of adhering to the positive temperature coefficient device of four the 7th embodiment, it is a curve map of verifying the accumulation of heat phenomenon of any part that does not adhere to temperature sensor.
Shown in curve map, under the situation of the general automatic temperature regulator of prior art, through accumulation of heat gradually, when finishing at the trial, the temperature at accumulation of heat position rises to 100 ℃, and under the situation of the anti-superheating system of the plane heater that utilizes positive temperature coefficient device of the present invention, the finishing material surface temperature of accumulation of heat maintains 50~55 ℃, thereby guarantees security.

Claims (10)

1. the manufacture method of a positive temperature coefficient device comprises the steps:
A) mix one or more macromolecule resins of from ethylene butyl acrylate copolymer, ethylene vinyl acetate copolymer, polyethylene glycol oxide, selecting, carbon black and the additive that average grain diameter is 70~300nm, mix synthetic with preparation;
B) form electrode and be made into the positive temperature coefficient device of film shape on described synthetic two sides; And
C) to described film irradiation electron ray, to carry out crosslinking Treatment.
2. the manufacture method of positive temperature coefficient device according to claim 1, it is characterized in that: described mixing synthetic comprises the macromolecule resin of 20~70 weight %, the carbon black of 30~80 weight % and the additive of 0.1~3 weight %.
3. the manufacture method of positive temperature coefficient device according to claim 1 is characterized in that: one or more the mixture of described additive for selecting from antioxidant, UV stabilizing agent and crosslinking agent.
4. the manufacture method of positive temperature coefficient device according to claim 1 is characterized in that: at described b) in the step, the thickness that forms the film of electrode is 0.2~3mm.
5. the manufacture method of positive temperature coefficient device according to claim 1 is characterized in that: at described c) in the step, electron ray is crosslinked to carry out under 5~320keV condition.
6. according to the manufacture method of each described positive temperature coefficient device in the claim 1 to 5, it is characterized in that: also be included in crosslinked back or make the step of annealing after the anti-overheat sensor cable.
7. the anti-overheat sensor cable of a plane heater, series connection is a plurality of seals by the positive temperature coefficient device that forms according to each described manufacture method manufacturing in the claim 1 to 6 and with insulating materials for they.
8. automatic temperature regulator, it detects the anti-overheat sensor cable of plane according to claim 7 heater and with the caloric value of this control plane heater.
9. plane heater heating system, it possesses according to anti-overheat sensor cable of each described plane heater of claim 7 or 8 or automatic temperature regulator.
10. combined type heating system, it possesses according to anti-overheat sensor cable of each described plane heater of claim 7 or 8 or automatic temperature regulator.
CN201010193737.1A 2010-02-16 2010-05-28 Manufacture method for positive temperature coefficient devices and anti-overheating system for plane heating element Expired - Fee Related CN102161245B (en)

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KR1020100013692A KR101129251B1 (en) 2009-10-13 2010-02-16 Method for manufacturing of ptc device and its system for preventing overheating of planar heaters using the same

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102875886A (en) * 2012-10-24 2013-01-16 浙江大学 EVA (ethylene vinyl acetate) microcapsule foam material and preparation method thereof
CN113715223A (en) * 2021-08-18 2021-11-30 厦门赛尔特电子有限公司 Method for improving resistance reduction of plug-in type PPTC (polyphenylene terephthalate) finished product

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4318881A (en) * 1980-05-19 1982-03-09 Raychem Corporation Method for annealing PTC compositions
CN1273674A (en) * 1998-07-08 2000-11-15 松下电器产业株式会社 Method for manufacturing chip PTC thermister
US20050092735A1 (en) * 2002-01-12 2005-05-05 Beurer Gmbh & Co Heating device comprising a flexible heating element
US20090206980A1 (en) * 2008-02-14 2009-08-20 Tdk Corporation Thermistor and manufacturing method thereof

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4318881A (en) * 1980-05-19 1982-03-09 Raychem Corporation Method for annealing PTC compositions
CN1273674A (en) * 1998-07-08 2000-11-15 松下电器产业株式会社 Method for manufacturing chip PTC thermister
US20050092735A1 (en) * 2002-01-12 2005-05-05 Beurer Gmbh & Co Heating device comprising a flexible heating element
US20090206980A1 (en) * 2008-02-14 2009-08-20 Tdk Corporation Thermistor and manufacturing method thereof

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102875886A (en) * 2012-10-24 2013-01-16 浙江大学 EVA (ethylene vinyl acetate) microcapsule foam material and preparation method thereof
CN113715223A (en) * 2021-08-18 2021-11-30 厦门赛尔特电子有限公司 Method for improving resistance reduction of plug-in type PPTC (polyphenylene terephthalate) finished product
CN113715223B (en) * 2021-08-18 2023-08-15 厦门赛尔特电子有限公司 Method for improving resistance value reduction of plug-in type PPTC finished product

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