CN112616207A - 用于可穿戴加热器的可拉伸聚合物厚膜炭黑组合物 - Google Patents
用于可穿戴加热器的可拉伸聚合物厚膜炭黑组合物 Download PDFInfo
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Abstract
一种聚合物厚膜炭黑组合物，其包含6‑13wt％的导电炭黑粉末；以及87‑94wt％的包含溶解在有机溶剂中的热塑性聚氨酯树脂的有机介质，所述组合物可用于在要求显著拉伸的应用中，特别是在可以高度伸长的基材上形成加热器的电阻元件，并且特别是可用于可穿戴服装应用中的加热器的电阻元件。
Description
技术领域
本发明涉及一种聚合物厚膜炭黑组合物。更具体地，所述聚合物厚膜炭黑组合物可以用于其中要求显著拉伸的应用中，特别是用于可以高度伸长的基材上形成加热器，并且特别是可用于可穿戴服装应用中的加热器。另一种方法利用直接在织造或针织服装织物上印刷，以产生可拉伸的加热器。
背景技术
聚合物厚膜(PTF)电路长期以来被用作电元件。虽然它们已被用作电元件，但PTF银或碳导体在高度可拉伸应用中的使用(如用于可穿戴服装) 并不常见。被拉伸和暴露于多次洗涤和干燥循环并仍然保持导电性的能力是关键的。本发明的目的之一是解决上述要求并生产可拉伸的PTF油墨，这些油墨可用于构建有待在基材上使用的功能电池，所述基材可用作可穿戴服装或者可以施用到可用作可穿戴服装的织物上。
可以印刷碳聚合物厚膜(PTF)糊料，以产生比由银糊料制成的干膜具有显著更大电阻的干膜。这使它们成为印刷的电阻加热器中电阻加热元件的理想候选物。银印刷电路可以为低电阻母线提供很少或没有寄生加热，从而为活性炭元素提供动力。在许多情况下，希望炭配制品固有的电阻的正温度系数(PTC)以限制最高工作温度。但是，在试图从小电源获取最大功率的加热器中，强大的PTC效应可能导致问题。如果设计为在工作温度下提供功率，则冷阻可能太低并且电流需求将触发电池的限流电路，从而导致关机。如果设计为在寒冷时可靠地开启，则加热器在温暖时可能无法提供足够的功率。需要在所需的工作温度范围内稳定的低PTC碳。
发明内容
本发明提供一种聚合物厚膜炭黑组合物，其包含：
(a)6-13wt％的导电炭黑粉末；以及
(b)87-94wt％的有机介质，所述有机介质包含10-30wt％的溶解在有机溶剂中的热塑性聚氨酯树脂，所述热塑性聚氨酯具有至少200％的百分比伸长率，其中所述热塑性聚氨酯树脂的重量百分比是基于所述有机介质的总重量并且所述导电炭黑粉末和所述有机介质的重量百分比是基于所述组合物的总重量。
本发明还涉及使用所述组合物形成用于要求可拉伸加热器的制品(例如可穿戴服装)的加热器的电阻部分。因此，本发明提供了一种制品，其包含由聚合物厚膜炭黑组合物形成的可拉伸加热器，所述聚合物厚膜炭黑组合物包含：
(a)6-13wt％的导电炭黑粉末；以及
(b)87-94wt％的有机介质，所述有机介质包含10-30wt％的溶解在有机溶剂中的热塑性聚氨酯树脂，所述热塑性聚氨酯具有至少200％的百分比伸长率，其中所述热塑性聚氨酯树脂的重量百分比是基于所述有机介质的总重量并且所述导电炭黑粉末和所述有机介质的重量百分比是基于所述组合物的总重量。
在一个实施例中，所述制品是可穿戴服装。
附图说明
图1描述了本申请可拉伸加热器的一个实例。
具体实施方式
本发明涉及一种用于形成加热器的聚合物厚膜炭黑组合物，并且特别是用于在高度可拉伸的电路如其中在织物或衣物上形成加热器的那些应用中的聚合物厚膜炭黑组合物。这经常被称为可穿戴电子产品。另外，所述组合物可用于在如加热座椅的应用中形成加热器。在基材上印刷并干燥导体层以便产生加热器，并且然后使整个电路经受织物将会受到的典型的弯曲/起折痕。另外，如对于织物典型的，它们必须在周期性基础上被洗涤并干燥，并且必须保持导体的导电性和完整性。
在此重量百分比写为wt％。
有机介质
有机介质包含溶解在有机溶剂中的热塑性聚氨酯树脂。聚氨酯树脂必须实现对下面的基材的良好粘附。在变形以及洗涤和干燥循环后，所述聚氨酯树脂必须与加热器的性能相容并且不会不利地影响加热器的性能。
所述热塑性聚氨酯树脂是所述有机介质的总重量的10-30wt％。在实施例中，所述热塑性聚氨酯树脂是聚氨酯均聚物。在另一个实施例中，所述聚氨酯树脂是基于聚酯的共聚物。在一个实施例中，所述热塑性聚氨酯树脂是主要是线性的羟基聚氨酯。
热塑性聚氨酯树脂具有至少200％的％伸长率。
百分比伸长率以通常的方式定义：
百分比伸长率＝最终长度-初始长度x100
初始长度
聚合物树脂典型地通过机械混合加入到有机溶剂中以形成所述介质。适合用于在聚合物厚膜组合物中使用的溶剂由本领域技术人员识别并且包括乙酸酯和萜烯，如卡必醇乙酸酯和α或
β萜品醇或其与其他溶剂如煤油、邻苯二甲酸二丁酯、丁基卡必醇、丁基卡必醇乙酸酯、己二醇和高沸点醇和醇酯的混合物。另外，可以包括在施用在基材上之后
用于促进快速硬化的挥发性液体。在本发明的许多实施例中，可使用溶剂如二醇醚、酮、酯和相似沸点(180℃至250℃)的其他溶剂、以及其混合物。配制这些溶剂和其他溶剂的各种组合，以获得所希望的粘度和挥发性要求。所用溶剂必须使树脂溶解。溶剂可以被添加到组合物中以调节粘度并且被认为是有机介质的一部分。
在各种实施例中，有机介质的量在基于所述组合物的总重量87至94 wt％。
导电炭黑组合物
许多碳复合膜包括石墨。使用适当载量的石墨很容易获得高电导率。然而，石墨片材之间的接触容易被聚合物基体的热膨胀破坏并且电阻随温度迅速增加。因此，在本发明组合物中使用高度结构化的炭黑(CB)粉末，如
XC-72和
700(均得自马萨诸塞州波士顿卡博特公司 (Cabot))。当适当分散时，炭黑可提供随着基质膨胀更难以破坏的导电网络。CB水平过低导致电阻过高并且电阻的正温度系数(PTC)也过高。电阻通常随着炭黑载量的增加而改善，直到碳颗粒的体积分数远高于该特定CB的渗透阈值为止。PTC也会随着CB浓度的增加而降低。当通过渗透阈值时，改进变得越来越小。然而，干膜中CB的载量过高会导致机械特性下降以及在干燥过程中形成裂纹。高剪切混合可用于提供更好的碳分散性，以降低渗透阈值，并在较低的CB载量下提供更好的电性能。这产生了更抗裂且低PTC的配制品。当使用标准PTF共混和辊磨设备和方法进行加工时，本发明的导电炭黑组合物形成具有可接受的低电阻率和低PTC的无裂纹膜。导电炭黑粉末的量是基于所述组合物的总重量6至13wt％。所述聚氨酯树脂的重量与所述导电炭黑粉末的重量之比是1.50至1.75。
当表面活性剂与溶剂和炭黑预共混时，一些额外的处理可以进一步改善分散性，但是表面活性剂不会像在高温处理的糊料中那样被燃烧掉并且因为膜中的挥发性化合物可能与皮肤接触而引起毒理学方面的担忧。
额外的粉末
可以将各种粉末或添加剂添加至PTF组合物中以改善粘附性、改变流变性以及增加低剪切粘度，从而改善可印刷性，只要它们对皮肤无有害作用。
PTF组合物的施用
将PTF炭黑组合物，也称为“糊料”，沉积在基材上，所述基材可用作可穿戴服装或可施用到可用作可穿戴服装的织物上。一种基材是热塑性聚氨酯基材，如从马萨诸塞州舍力毕玛时联合公司(Bemis Associates,Inc., Shirley,MA)可获得的Bemis ST-604。另一种可能的基材是热塑性聚酯，如从美国特拉华州威明顿的杜邦公司(DuPont Co.,Wilmington,DE)可获得的
所述基材还可以是由塑料片材与其上沉积的可渗透涂层的组合构成的复合材料片材。
典型地通过丝网印刷进行PTF炭黑组合物在基材上的沉积，但可利用其他沉积技术，如模版印刷、注射式滴涂或涂覆技术。在丝网印刷的情况下，筛网尺寸控制沉积的厚膜的厚度。
一般来讲，厚膜组合物包含给予组合物适当功能特性的功能相。例如，功能相可包含分散于有机介质中的电功能粉末，有机介质充当功能相的载体。一般来讲，烧制所述组合物以烧尽有机介质的聚合物和溶剂二者并给予电功能特性。然而，在聚合物厚膜组合物的情况下，有机介质的聚合物部分在干燥后作为组合物的组成部分保留。
在除去所有溶剂所必需的时间内和温度下加工PTF炭黑组合物。例如，通过暴露于130℃的热下持续典型地10-15分钟来干燥沉积的厚膜。
加热器构造
按照上述条件，在基材上印刷PTF炭黑组合物并使其干燥。可以在基材上印刷一个或多个PTF炭黑电阻组合物层并干燥，以形成电池的电阻元件。可以在PTF炭黑电阻组合物之前或之后印刷总线和母线的导体。
在一个实施例中，可以将基材施用到可用于形成可穿戴服装的织物上。基材的任一侧可以施用到织物上，即，基材的具有炭黑膜的侧面可以与织物相邻，或者基材的另一侧可以与织物相邻。热塑性聚氨酯基材，如 DuPontTM IntexarTM TE11C或Bemis ST-604，粘附到聚酯、尼龙和聚氨酯或聚氯乙烯涂覆的织物上，
在另一个实施例中，炭黑组合物可以直接使用到可拉伸的可渗透织物上。一种这样的非织造织物是由从法国科尔马Fruedenberg Evolon公司 (Fruedenberg Evolon,Colmar,France)可获得的
构造的。可以用于这种类型的施用的另一种可渗透基材是涂覆有聚酰胺的织造聚酯，例如从日本京都达尼克公司(Dynic Corp,Kyoto,Japan)可获得的
OS5000U。
实例和对比实验
实例1
PTF炭黑组合物按以下方式制备。使用69重量份的初始有机介质并且所述有机介质通过混合28.50wt％的
406聚氨酯(宾夕法尼亚州匹兹堡科思创有限责任公司(Covestro LLC,Pittsburgh,PA))与71.50wt％的DowanolTM DPM二丙二醇甲醚(密歇根州米德兰陶氏公司(Dow Co., Midland MI))有机溶剂制备。将此混合物在90℃下加热1-2小时以溶解所有树脂。添加12.31重量份的
XC-72导电炭黑粉末(马萨诸塞州波士顿卡博特公司)。最后，为了稀释目的添加18.69重量份的DowanolTM DPM二丙二醇甲醚以使组合物达到所希望的70Pas的粘度。包括添加以调节粘度的溶剂在内的有机介质的量为87.70wt％，其由68.03wt％的溶剂和 19.67wt％的聚氨酯树脂组成，其中wt％是基于组合物的总重量。所述聚氨酯树脂是所述有机介质的总重量的22.4wt％。所述聚氨酯树脂的重量与所述炭黑的重量之比是1.60。
将此组合物在行星式混合器上混合30分钟，并且然后在三辊轧机上进行数次通过以提供炭黑粉末的良好分散。
将所述组合物丝网印刷在聚酯(PET)基材上并在130℃下，在强制加热箱干燥10分钟。在此干燥过程中没有裂纹形成。在干燥膜中炭黑的体积百分比为36.6。
干燥膜的电阻率为162欧姆/平方。通过在25℃、40℃和65℃下测量膜的电阻获得了PTC的指示。在40℃下的PTC电阻系数(在40℃下的电阻比在25℃下的电阻的比率)为1.06，并且在65℃下的PTC电阻系数(在 65℃下的电阻比在25℃下的电阻的比率)为1.18，表明相对较低的PTC。
实例2
PTF炭黑组合物按以下方式制备。使用84.2重量份的初始有机介质并且所述有机介质通过混合20.50wt％的
530/1聚氨酯(宾夕法尼亚州匹兹堡科思创有限责任公司)与79.50wt％的二乙二醇乙基乙酸酯(田纳西州金斯波特伊士曼化工有限公司(Eastman Chemical Co.,Kingsport, Tenn.))有机溶剂制备。将此混合物在90℃下加热1-2小时以溶解所有树脂。添加10.80重量份的
XC-72导电炭黑粉末(马萨诸塞州波士顿卡博特公司)。最后，为了稀释目的添加5.00重量份二乙二醇乙基乙酸酯以使组合物达到所希望的70Pas的粘度。包括添加以调节粘度的溶剂在内的有机介质的量为89.2wt％，其由71.94wt％的溶剂和17.26wt％的聚氨酯树脂组成，其中wt％是基于组合物的总重量。所述聚氨酯树脂是该有机介质的总重量的19.4wt％。所述聚氨酯树脂的重量与所述炭黑的重量之比是 1.60。
将此组合物在行星式混合器上混合30分钟，并且然后在三辊轧机上进行数次通过以提供炭黑粉末的良好分散。
将所述组合物丝网印刷在聚酯(PET)基材上并在130℃下，在强制加热箱干燥10分钟。在此干燥过程中没有裂纹形成。在干燥膜中炭黑的体积百分比为36.6。
干燥膜的电阻率为187欧姆/平方。通过在25℃、40℃和65℃下测量膜的电阻获得了PTC的指示。在40℃下的PTC电阻系数(在40℃下的电阻比在25℃下的电阻的比率)为1.14，在65℃下的PTC电阻系数(在65℃下的电阻比在25℃下的电阻的比率)为1.28，表明相对较低的PTC。
实例3
PTF炭黑组合物按以下方式制备。使用58.50重量份的初始有机介质并且所述有机介质通过混合20.50wt％的
530/1聚氨酯(宾夕法尼亚州匹兹堡科思创有限责任公司)与79.50wt％的二乙二醇乙基乙酸酯 (田纳西州金斯波特伊士曼化工有限公司)制备。将此混合物在90℃下加热1-2小时以溶解所有树脂。添加7.00重量份的
XC-72导电炭黑粉末(马萨诸塞州波士顿卡博特公司)。最后，为了稀释目的加入34.50 重量份二乙二醇乙基乙酸酯以使组合物达到所希望的70Pas的粘度。包括添加以调节粘度的溶剂在内的有机介质的量为93.00wt％，其由81.01wt％的溶剂和11.99wt％的聚氨酯树脂组成，其中wt％是基于组合物的总重量。所述聚氨酯树脂是该有机介质的总重量的12.9wt％。所述聚氨酯树脂的重量与所述炭黑的重量之比是1.71。
将此组合物在行星式混合器上混合30分钟，并且然后在三辊轧机上进行数次通过以提供炭黑粉末的良好分散。
将所述组合物丝网印刷在聚酯(PET)基材上并在130℃下，在强制加热箱干燥10分钟。在此干燥过程中没有裂纹形成。在干燥膜中炭黑的体积百分比为35。
干燥膜的电阻率为179欧姆/平方。通过在25℃、40℃和65℃下测量膜的电阻获得了PTC的指示。在40℃下的PTC电阻系数(在40℃下的电阻比在25℃下的电阻的比率)为1.11，在65℃下的PTC电阻系数(在65℃下的电阻比在25℃下的电阻的比率)为1.24，表明相对较低的PTC。
实例4
PTF炭黑组合物按以下方式制备。使用66.07重量份的初始有机介质并且所述有机介质通过混合27.50wt％的
406聚氨酯(宾夕法尼亚州匹兹堡科思创有限责任公司)与72.50wt％的DowanolTM DPM二丙二醇甲醚(密歇根州米德兰陶氏公司)有机溶剂制备。将此混合物在90℃下加热1-2小时以溶解所有树脂。添加12.00重量份的
XC-72导电炭黑粉末(马萨诸塞州波士顿卡博特公司)。添加0.06重量份的表面活性剂。最后，为了稀释目的添加18.17重量份的DowanolTM DPM二乙二醇乙基乙酸酯以使组合物达到所希望的70Pas的粘度。包括添加以调节粘度的溶剂在内的有机介质的量为87.40wt％，其由69.23wt％的溶剂和18.17wt％的聚氨酯树脂组成，其中wt％是基于组合物的总重量。所述聚氨酯树脂是该有机介质的总重量的20.7wt％。所述聚氨酯树脂的重量与所述炭黑的重量之比是1.51。
将此组合物在行星式混合器上混合30分钟，并且然后在三辊轧机上进行数次通过以提供炭黑粉末的良好分散。
将所述组合物丝网印刷在聚酯(PET)基材上并在130℃下，在强制加热箱干燥10分钟。在此干燥过程中没有裂纹形成。在干燥膜中炭黑的体积百分比为37。
干燥膜的电阻率为122欧姆/平方。通过在25℃和40℃下测量膜的电阻获得了PTC的指示。在40℃下的PTC电阻系数(在40℃下的电阻比在 25℃下的电阻的比率)为1.2，表明相对较低的PTC。
对比实验A
PTF炭黑组合物按以下方式制备。使用61.07重量份的初始有机介质并且所述有机介质通过混合27.50wt％的
406聚氨酯(宾夕法尼亚州匹兹堡科思创有限责任公司)与72.50wt％的DowanolTM DPM二丙二醇甲醚(密歇根州米德兰陶氏公司)有机溶剂制备。将此混合物在90℃下加热1-2小时以溶解所有树脂。添加13.00重量份的
XC-72导电炭黑粉末(马萨诸塞州波士顿卡博特公司)。添加0.06重量份的表面活性剂。最后，为了稀释目的加入25.33重量份DowanolTM DPM二乙二醇乙基乙酸酯以使组合物达到所希望的70Pas的粘度。包括添加以调节粘度的溶剂在内的有机介质的量为86.40wt％，其由69.61wt％的溶剂和16.79wt％的聚氨酯树脂组成，其中wt％是基于组合物的总重量。所述聚氨酯树脂是该有机介质的总重量的19.4wt％。所述聚氨酯树脂的重量与所述炭黑的重量之比是1.29。
将此组合物在行星式混合器上混合30分钟，并且然后在三辊轧机上进行数次通过以提供炭黑粉末的良好分散。
将所述组合物丝网印刷在聚酯(PET)基材上并在130℃下，在强制加热箱干燥10分钟。在干燥过程中发生了裂纹形成。在干燥膜中炭黑的体积百分比为40.8。较高的炭黑相对含量导致了裂纹。
对比实验B
PTF炭黑组合物按以下方式制备。使用69重量份的初始有机介质并且所述有机介质通过混合28.50wt％的
406聚氨酯(宾夕法尼亚州匹兹堡科思创有限责任公司)与71.50wt％的DowanolTM DPM二丙二醇甲醚(密歇根州米德兰陶氏公司()有机溶剂制备。将此混合物在90℃下加热1-2小时以溶解所有树脂。添加4.45重量份的
XC-72导电炭黑粉末(马萨诸塞州波士顿卡博特公司)以及11.1重量份的石墨。最后，为了稀释目的添加35.93重量份的DowanolTM DPM二丙二醇甲醚以使组合物达到所希望的70Pas的粘度。包括添加以调节粘度的溶剂在内的有机介质的量为84.45wt％，其由67.77wt％的溶剂和16.68wt％的聚氨酯树脂组成，其中wt％是基于组合物的总重量。所述聚氨酯树脂是该有机介质的总重量的19.7wt％。所述聚氨酯树脂的重量与所述炭黑和石墨的总重量之比是1.07。
将此组合物在行星式混合器上混合30分钟，并且然后在三辊轧机上进行数次通过以提供炭黑粉末的良好分散。
将所述组合物丝网印刷在聚酯(PET)基材上并在130℃下，在强制加热箱干燥10分钟。在此干燥过程中没有裂纹形成。在干燥膜中炭的体积百分比为37.5。
干燥膜的电阻率为150欧姆/平方。通过在25℃、40℃和65℃下测量膜的电阻获得了PTC的指示。在40℃下的PTC电阻系数(在40℃下的电阻比在25℃下的电阻的比率)为2.2，并且在65℃下的PTC电阻系数(在65℃下的电阻比在25℃下电阻的的比率)为2.9，表明由于存在石墨相对较高的PTC。
Claims (12)
1.一种聚合物厚膜炭黑组合物，其包含：
(a)6-13wt％的导电炭黑粉末；以及
(b)87-94wt％的有机介质，所述有机介质包含10-30wt％的溶解在有机溶剂中的热塑性聚氨酯树脂，所述热塑性聚氨酯具有至少200％的百分比伸长率，其中所述热塑性聚氨酯树脂的重量百分比是基于所述有机介质的总重量并且所述导电炭黑粉末和所述有机介质的重量百分比是基于所述组合物的总重量。
2.如权利要求1所述的聚合物厚膜炭黑组合物，其中，所述聚氨酯树脂的重量与所述导电炭黑粉末的重量之比是1.50至1.75。
3.如权利要求1所述的聚合物厚膜炭黑组合物，其中，所述热塑性聚氨酯树脂选自由以下组成的组：基于聚酯的聚合物、氨基甲酸酯均聚物和主要是线性的羟基聚氨酯。
4.如权利要求3所述的聚合物厚膜炭黑组合物，其中，所述热塑性聚氨酯树脂是主要是线性的羟基聚氨酯。
5.一种制品，其包括具有由聚合物厚膜炭黑组合物形成的电阻元件的可拉伸加热器，所述聚合物厚膜炭黑组合物包含：
(a)6-13wt％的导电炭黑粉末；以及
(b)87-94wt％的有机介质，所述有机介质包含10-30wt％的溶解在有机溶剂中的热塑性聚氨酯树脂，所述热塑性聚氨酯具有至少200％的百分比伸长率，其中所述热塑性聚氨酯树脂的重量百分比是基于所述有机介质的总重量并且所述导电炭黑粉末和所述有机介质的重量百分比是基于所述组合物的总重量。
6.如权利要求5所述的制品，其中，所述聚氨酯树脂的重量与所述导电炭黑粉末的重量之比是1.50至1.75。
7.如权利要求5所述的制品，其中，所述热塑性聚氨酯树脂选自由以下组成的组：基于聚酯的聚合物、氨基甲酸酯均聚物和主要是线性的羟基聚氨酯。
8.如权利要求7所述的制品，其中，所述热塑性聚氨酯树脂是主要是线性的羟基聚氨酯。
9.如权利要求5-8中任一项所述的制品，其中，所述制品是可穿戴服装。
10.一种制品，其包括具有聚合物厚膜炭黑电阻元件的可拉伸加热器，其中所述聚氨酯树脂的重量与炭黑的重量之比1.50至1.75
11.如权利要求10所述的制品，其中，所述热塑性聚氨酯树脂是主要是线性的羟基聚氨酯。
12.如权利要求10或11所述的制品，其中，所述制品是可穿戴服装。
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| US5344591A (en) * | 1990-11-08 | 1994-09-06 | Smuckler Jack H | Self-regulating laminar heating device and method of forming same |
| CN1472240A (zh) * | 2002-06-19 | 2004-02-04 | ��Ļ���Ű˾ | 锌聚合物厚膜组合物 |
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