CN1543264A - Low cost heating devices manufactured from conductive loaded resin-based materials - Google Patents
Low cost heating devices manufactured from conductive loaded resin-based materials Download PDFInfo
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- CN1543264A CN1543264A CNA2004100387434A CN200410038743A CN1543264A CN 1543264 A CN1543264 A CN 1543264A CN A2004100387434 A CNA2004100387434 A CN A2004100387434A CN 200410038743 A CN200410038743 A CN 200410038743A CN 1543264 A CN1543264 A CN 1543264A
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Images
Classifications
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/10—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor
- H05B3/12—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor characterised by the composition or nature of the conductive material
- H05B3/14—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor characterised by the composition or nature of the conductive material the material being non-metallic
- H05B3/145—Carbon only, e.g. carbon black, graphite
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/10—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/10—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor
- H05B3/12—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor characterised by the composition or nature of the conductive material
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
- H05B2203/002—Heaters using a particular layout for the resistive material or resistive elements
- H05B2203/003—Heaters using a particular layout for the resistive material or resistive elements using serpentine layout
Landscapes
- Resistance Heating (AREA)
- Surface Heating Bodies (AREA)
- Central Heating Systems (AREA)
Abstract
Heating devices are formed of a conductive loaded resin-based material. The conductive loaded resin-based material comprises micron conductive powder(s), conductive fiber(s), or a combination of conductive powder and conductive fibers in a base resin host. The ratio of the weight of the conductive powder(s), conductive fiber(s), or a combination of conductive powder and conductive fibers to the weight of the base resin host is between about 0.20 and 0.40. The micron conductive powders are formed from non-metals, such as carbon, graphite, that may also be metallic plated, or the like, or from metals such as stainless steel, nickel, copper, silver, that may also be metallic plated, or the like, or from a combination of non-metal, plated, or in combination with, metal powders. The micron conductor fibers preferably are of nickel plated carbon fiber, stainless steel fiber, copper fiber, silver fiber, or the like. The conductive loaded resin-based heating devices can be formed using methods such as injection molding compression molding or extrusion. The conductive loaded resin-based material used to form the heating devices can also be in the form of a thin flexible woven fabric that can readily be cut to the desired shape.
Description
Technical field
The present invention relates to heater, and particularly relate to heater by conductive loaded resin-based materials mold moulding, this material comprises a micron electroconductive powder, micron conducting fibre or the two combination, and when the mold moulding, above-mentioned material evenly mixes in base resin.The material that this manufacture process obtains the conductivity part or can use in EMF or electronic spectrum.
The present patent application requirement applying date is that the U.S. Provisional Patent Application 60/461,877 and the applying date on April 10th, 2003 is the priority of the U.S. Provisional Patent Application 60/478,774 on June 16th, 2003.Quote it in the lump in full as a reference at this.
Present patent application is that sequence number is 10/309,429, the applying date is the part continuation application of the U.S. Patent application INT01-002CIP on December 4th, 2002, also quote it in the lump in full as a reference at this, above-mentioned sequence number is 10/309,429 U.S. Patent application also is that sequence number is 10/075,778, the applying date is on February 14th, 2002, files (docket) number are the part continuation application of the U.S. Patent application of INT01-002, this sequence number is 10/075, it is 60/317,808 that 778 U.S. Patent application has required sequence number, and the applying date is September 7 calendar year 2001, sequence number is 60/269,414, the applying date is that February 16 calendar year 2001 and sequence number are 60/317,808, the applying date is the priority of the U.S. Provisional Patent Application in February 15 calendar year 2001.
Background technology
Temperature control equipment from general kitchen application is used to high-end science generally uses stratie in application.Most of heating element is the high-resistance metal electric wire, and for example nickel-chromium (nichrome) or tungsten are designed to be provided for heating required necessary resistance.The resistance of this heating element is by resistivity, cross-sectional area and the length decision of electric wire.The heat that heating element produces is by the electric current decision by this heating element.Generally speaking, heating element also comprises the cladding material as electric insulation and heat conductor.
The heat that stratie produces arrives heated object by conduction, convection current and/or radiant transfer.Conduction heat transfer depends on the direct contact between heating element and the heated object, and for example, the heat transmission from the electric furnace to the metal pan is transmitted by conduction basically.Convective heat transfer depends on fluid and flows and transmit heat, and for example, the convection current that the culinary art egg depends on current in the boiling water pot is delivered to egg by water from metal pan with heat.Overheated its density that causes of the water of pot bottom reduces, thus the liter waterborne in the bottom of a pan, and the water of these risings is given thermal energy transfer in the egg that floats in the water.On the contrary, colder and density is bigger at the water at pot top, therefore, the water at pot top can sink to the bottom of a pan.Thereby in this pot water, formed the convection current of current.Transfer of radiant heat depends on electromagnetic energy (for example light) heat is delivered to object from heating element.The bread part of for example, toasting in electric oven is heated by the heat from luminous heating element radiation.Radiation heating also is the mode that solar energy arrives the earth.In actual applications, find that these three kinds of thermaltransmission modes influence each other and often generation simultaneously.
The stratie that uses in various heating systems and use is better than for example based on the heating source that burns.Electrical heating elements does not produce harmful or suffocative smog.Electrical heating elements is by the signal of telecommunication and further can be precisely controlled by digital circuit.Electrical heating elements can be made multiple shape, its can under the thermal loss of minimum near object produce the heat of concentrating very much, it can produce heat, fluid under the situation that does not have oxygen, even inflammable fluid also can heat by designing stratie suitably.
Yet the stratie of current use has some shortcomings in this area.Therefore the element of Metal Substrate, particularly nichrome and tungsten, quality is more crisp, is not suitable for the application that need heat with the pliability heating element.In addition, in many products are used bigger thermal cycle and the brittleness of these materials will cause thermal fatigue.Other hardware, for example the copper base member has been brought bigger pliability.Yet if this application need resistive element changes or bending position, this resistive element will damage because of metal fatigue.The Metal Substrate stratie generally forms metal cords, and these elements cost an arm and a leg, the Temperature Treatment that demand is very high, and shape is limited.When breakage took place, this breakage was generally by due to the fatigue described above in addition, and so whole element can not use and must change.
Following is several inventions formerly that relate to Markite.Authorize the United States Patent (USP) 4,197,218 of McKaveney and described the conductivity article, these article constitute with the non-conductive matrix that comprises in small, broken bits granular ferroalloy, silicon alloy or the mixture that are dispersed with conductivity.Authorize the United States Patent (USP) 5,771,027 of Marks etc. and described the combined antenna that has grid, this grid comprises that electric conductor strengthens fabric as the resin that warp thread inweaves, and forms one deck of the multiple-layer laminated structure of this antenna.Authorize Solberg, people's such as Jr. United States Patent (USP) 6,249,261 has been described the bearing measurement antenna, and this antenna is made of conducting polymer composite material, and this polymer composites replaces traditional metal material.Authorize the United States Patent (USP) 6,277,303 of Foulger and described the conducting polymer composite material, this conducting polymer composite material comprises the secondary phase material with merocrystalline polymer.This composite material also comprises the conductivity packing material that is dispersed in the secondary phase material, and this packing material has enough amounts, and this amount is equal to or greater than and produces the required amount of conduction network that continues in secondary phase material.This composite material also comprises the principal phase material, and this principal phase material is a polymer, will not promote the electrostatic interaction of mixed phase ability when this principal phase material mixes with secondary phase material.This principal phase material has the secondary phase material that is dispersed in wherein, and the amount of this secondary phase material is equal to or greater than to produce in the principal phase material and continues the required amount of conduction network.Then, this compound forms and has the difference semiconduction ternary complex of continuous phase altogether.
Authorize people's such as Starz United States Patent (USP) 6,558,746 and describe a kind of coating composition that is used to make conductive coating in detail, comprise one or more conductive pigments and organic binder bond.This coating composition selectively comprises additive and auxiliary agent.The coating of Huo Deing has excellent especially caking property like this, anti-mechanical influence and anti-solvent, and demonstrated suitable conductivity (surface resistivity) value.The United States Patent (USP) 6,602,446 of authorizing Ushijima provides a kind of conducting resinl of being made by conductive filler to combine with heating element, is suitable for producing heat with electromagnetic induction.This conducting resinl and mixed with resin.In addition, the NvBekaertsa in Belgian Kortrijk city makes Metal Yarns, knitting metal fabric, the metallic fiber of cut-out and sheet and sintered porous media.This commercially available fiber has from the diameter of 1 μ m to 20 μ m, and can be to be cut off into short fiber segment or continuous long filament.On January 25th, 2003 existed
Www.bekaert.comMetal shown in the middle product description of finding is stainless steel, heat-resisting alloy, nickel and nickel alloy, titanium, aluminium and copper.Sbenaty write " I want my pizza heating! " in this piece article (" science, technology, engineering and mathematical education magazine "; in January, 2000-April; the 1st volume; the 1st phase); one of them designed application has been described and has been used for for example heating element of pizza of family supply food, and this heating element has utilized the material of being made up of the flexual conductive polymer material that is connected between the global copper bus line.
" high conductivity and flexual ultra micro synthetic material are provided " this piece article (" for the third time about the bonding and coating technology international conference collection of thesis in the electronic manufacturing technology " of writing people such as McCluskey, 1998, the 282-286 page or leaf) in, a kind of machinery and electric property of the electric conductive polymer of being made by conductive silver thin slice ultramicron filler described.The use of ultra micro filler makes this material obtain the conductivity with traditional filled polymer par under significantly lower particulate is filled.This electric conductive polymer has the high conductivity of filled polymer and the pliability and the low-density of stability and inherent electric conductive polymer concurrently.The determined size that has between 200nm and 20 μ m of this ultramicron metal charge, and when mixing, have the resistance value of 10-1000hm-cm with non-conductive polymer substrate.In addition, it is the silver of 3 μ m-20 μ m when being 65-75% with respect to the silicones weight rate that people such as McCluskey have discussed particle size, and silver is filled silicones and begun to have conductivity.The silver of the particulate of 200nm is that silver is filled silicones and begun to have conductivity under the situation of 35-40% with respect to the silicones weight rate.
Summary of the invention
Main purpose of the present invention is to provide effective heater.
The present invention also aims to provide a kind of method that forms heater.
The present invention also aims to provide a kind of heater by conductive loaded resin-based materials mold moulding.
The present invention also aims to provide the heater by conductive loaded resin-based materials mold moulding, the performance of this heater can be selected based on the conductive material that mixes in resin-based materials.
The present invention also aims to provide the heater by conductive loaded resin-based materials mold moulding, the performance of this heater can be selected based on the performance of the resin-based materials of selecting for use.
The present invention also aims to provide the method for making heater in conjunction with different material shape from conductive loaded resin-based materials.
The present invention also aims to provide a series of heater that has conductivity filled resin base material heating element.
According to purpose of the present invention, obtained a kind of heater.This heater comprises heating element, and this element is included in the conductive loaded resin-based materials that comprises conductive material in the base resin matrix.First terminal is connected in first end of heating element, and second terminal is connected in second end of heating element.
According to purpose of the present invention, also obtained a kind of heater.This heater comprises heating element, and this element is included in the conductive loaded resin-based materials that comprises conductive material in the base resin matrix, and this conductive material comprises the combination of electroconductive powder and conducting fibre.One electric insulation layer coats this heating element.First terminal is connected in first end of heating element, and second terminal is connected in second end of heating element.
According to purpose of the present invention, also obtained a kind of method that forms the heating element device.This method comprises and is provided at the conductive loaded resin-based materials that comprises conductive material in the resinous substrates that this conductive loaded resin-based materials mold is shaped to the heating element device.
Description of drawings
The part material of the present invention that forms is shown in following accompanying drawing:
Fig. 1 a and first preferred embodiment of 1b diagram the present invention show the heater that comprises conductive loaded resin-based materials.
Fig. 2 illustrates first preferred embodiment of conductive loaded resin-based materials, and wherein this conductive material comprises powder.
Fig. 3 illustrates second preferred embodiment of conductive loaded resin-based materials, and wherein this conductive material comprises a micron conducting fibre.
Fig. 4 illustrates the 3rd preferred embodiment of conductive loaded resin-based materials, and wherein this conductive material comprises electroconductive powder and micron conducting fibre.
Fig. 5 a and 5b illustrate the 4th preferred embodiment, and wherein conductive fabric class material is formed by conductive loaded resin-based materials.
The simplified schematic structure chart of Fig. 6 a and 6b diagram injection moulding device and extrusion molding shaped device, this device can be used for the conductor circuit of mold moulding electroconductive resin sill.
Fig. 7 illustrates second preferred embodiment of the present invention, shows the heater of the conductive loaded resin base of spirality heating resistance pad form.
The 3rd preferred embodiment of Fig. 8 a and 8b diagram the present invention the heated seat device of conductive loaded resin base.
Fig. 9 illustrates the 4th preferred embodiment of the present invention, shows the heating window device of conductive loaded resin base.
Figure 10 illustrates the 5th preferred embodiment of the present invention, shows the heated mirror device of conductive loaded resin base.
Figure 11 illustrates the 6th preferred embodiment of the present invention, shows the radiation floor heater of conductive loaded resin base.
Figure 12 illustrates the 7th preferred embodiment of the present invention, shows the heating tape device of conductive loaded resin base.
Figure 13 illustrates the 8th preferred embodiment of the present invention, shows the cartridge heater device of conductive loaded resin base.
Figure 14 illustrates the 9th preferred embodiment of the present invention, shows the immersion heater device of conductive loaded resin base.
Figure 15 illustrates the tenth preferred embodiment of the present invention, shows the flange-cooled strip heater device of conductive loaded resin base.
Figure 16 illustrates the 11 preferred embodiment of the present invention, shows the pliability heater that the conductive loaded resin base of thermal compensation is provided for electronic equipment.
Figure 17 illustrates the 12 preferred embodiment of the present invention, shows the band or the bar heater of conductive loaded resin base.
Figure 18 illustrates the 13 preferred embodiment of the present invention, shows the heating tube device of conductive loaded resin base injection moulding.
Figure 19 illustrates the 14 preferred embodiment of the present invention, shows the heating tube device of conductive loaded resin base.
Figure 20 to 22 illustrates the 15 preferred embodiment of the present invention, shows the tubular heating device of conductive loaded resin base, and this device is used for hot-water heater and heating towel rack.
Embodiment
The present invention relates to the heater by conductive loaded resin-based materials mold moulding, this material comprises a micron electroconductive powder, and micron conducting fibre, or the two combination evenly mix in base resin when the mold moulding.
Conductive loaded resin-based materials of the present invention is the base resin of filling conductive material, and this makes any base resin become conductor but not insulator.This resin provides structural intergrity for the mold moulding section.This micron conducting fibre, micron electroconductive powder or both combinations evenly mix in resin in the mold forming process, provide electric power to connect.
This conductive loaded resin-based materials can be by the mold moulding, extrusion molding moulding or provide almost any desirable shape or size with class methods.The conductive loaded resin-based materials of mold moulding also can cut, mold pressing or from injection moulding or extruding layer or bar form vacuum, cover the mold moulding, laminated, grind or provide desirable shape and size with class methods.Utilize the heat conduction of the heater that conductive loaded resin-based materials makes or the composition that electric conductivity depends on this conductive loaded resin-based materials, the parameter that can adjust this filling or interpolation is with structure, electricity or other physical property of this material of helping to obtain wishing.The selected material use mold forming technique that is used to make heater with or for example injection moulding, cover mold moulding, thermosetting resin, cold soaking, extrusion molding or similar method and evenly mix together.The performance that relates to 2D, 3D, 4D and 5D design, mold moulding and electric property, comprise physics and electrical advantages, the polymer physics in can the conductive network in the mold forming process of substantial portion and in the material of mold moulding section or moulding connects and reaches.
In the manufacturing of heater, by being desirable shape and size with these forming materials, the use of conductive loaded resin-based materials has significantly reduced inventory charge, and design and manufacture process are controlled close tolerance easily.Utilize conventional for example injection moulding of forming method, cover mold moulding or extrusion molding moulding or same class methods, this heater can be made arbitrary shape and size.When this conductive loaded resin-based materials mold moulding, the hope scope of application of resistivity generally but not exclusively make approximately every square 5 to 25ohms, but by changing the resistivity that doping parameters and/or Choice of Resin can obtain other value.
This conductive loaded resin-based materials comprises a micron electroconductive powder, micron conducting fibre, or any combination of the two, in the mold forming process, above-mentioned material mixes in base resin, is easy to produce low cost, conductivity, the fabrication portion of close tolerance or circuit.This micron electroconductive powder can be carbon, graphite, amine or allied substances, and/or metal dust for example nickel, copper, silver or plating material or allied substances.The powder of carbon or other form for example use of graphite etc. can produce additional low-level electron exchange, and when uniting use with the micron conducting fibre, can be created in the micron packing elements in the fiber micron conduction network, thereby produce further electron exchange, also as the lubricant of mold former.This micron conducting fibre can be nickel-coated carbon fibers, stainless steel fibre, copper fiber, silver-colored fiber or allied fiber, or above-mentioned composition.This structural material is a polymer resin arbitrarily, this structural material of giving an example can but not exclusive having, Morocco, Field city now, the polymer resin that GEPLASTICS produces; Morocco, Field city now, other serial plastics that GEPLASTICS produces; , by other serial plastics of other manufacturer's production; New York, the Waterford,, the silicones that GESILICONES produces; , or other pliability resin-based rubber composite of producing by other manufacturer.
This has loaded the micron electroconductive powder, the micron conducting fibre, or the resin-based structural material of the two combination, can utilize conventional mold forming method for example injection moulding or covering mold moulding, or the extrusion molding moulding produces desirable shape and size.The conductive loaded resin-based materials of this mold moulding also can by required by mold pressing, cut or roll form to produce the heater of desirable shape formative element.The composition of the interpolation in the base resin of this filling and the directive effect that combines with micron conductive can influence the electricity and the structural behaviour of this heater, also can and or extrude design and or precisely controlled in the mold forming process by Mould design, running gate system.In addition, can select this resin-based to obtain for example very high fusing point of desirable hot property or specific thermal conductivity.
Also can make the resin-based composite bed with micron stainless steel fibre or other conducting fibre formation textile-like material random or that continuous fibers are netted.The conducting fibre of this mesh-like can be laminated or be used with class methods and for example be attached to spy not jade for asking rain, polyester or any resin-based pliability or solid material, when its fiber content, direction and shape are designed respectively, the very dry goods material of the flexible of high conductivity will be produced.Such dry goods material also can for example rubber or plastics be the same with other resin material, use as imbedding the heater in the human clothes.When and when using conducting fibre as the netted conductor of the part of laminated thing or dry goods material, this fiber can have the diameter between about 3 and 12 microns, general between about 8 and 12 microns or in about 10 microns scope, length can be seamless or overlapping.
By micron conducting fibre and/or micron electroconductive powder and the base resin of selecting anticorrosive and/or anti-electrolytic etching of metal, conductive loaded resin-based materials of the present invention can be made anticorrosive and/or anti-electrolytic etching of metal.For example, if anticorrosive/anti-electrolysis base resin combines with stainless steel fibre and carbon fiber/powder, just obtained a kind of anticorrosive and/or electrolytic etching of metal conductive loaded resin-based materials.Other additional feature with important of the present invention is that conductive loaded resin-based materials of the present invention can be made the material that possesses anti-flammability, selects fire retardant (FR) base resin material to make final products show fire resistance.Aforesaid performance is particularly important in the application of heating element.
Among the present invention, the even mixing of micron conducting fibre and/or micron electroconductive powder and base resin also can be called doping.That is to say that evenly mixed process makes general non-conductive base resin change conductive material into.This process is similar to the doping process of semi-conducting material, and for example silicon can change conductive material into by the known introducing donor/acceptor of field of semiconductor devices ion technology.Therefore, the term doping that the present invention uses, expression makes general non-conductive base resin change conductive material into by micron conducting fibre and/or micron electroconductive powder evenly are mixed into base resin.
Additional and important feature of the present invention, promptly the conductive loaded resin-based materials of this mold moulding has shown excellent heat conductivility.Therefore, the heater by the conductive loaded resin-based materials manufacturing of this mold moulding can provide more heat-exchange capacity for application.
With reference to accompanying drawing 1a and 1b, be the diagram of first preferred embodiment of the present invention, show below and several key character of the present invention is discussed.Referring now to Fig. 1 a, diagram is according to the stratie 12 of conductive loaded resin-based materials of the present invention, and this heating element 12 comprises the solid band 16 of conductive loaded resin-based materials, this solid band and power supply V
Heat14 connect.This conductive loaded resin-based materials has conductivity.By adjusting the correlative or the type of conductive material in the base resin, can easily adjust the volume resistivity of this material.The volume resistivity that the resistance value of this heating element 12 equals this conductive loaded resin-based materials multiply by the cross-sectional area of the straight length of this element divided by this element.Base resin material can be selected based on many factors, for example mechanical strength, flexible, outward appearance, anticorrosive/electrolyte, anti-flammability, chemical property, working properties, transparency/opacity, cost etc., and in using to the requirement of heat.For example, when selecting to be used for the material of given heating element, must consider the glassy state temperature or the maximum operating temp of the resin-based materials of mold moulding.According to the present invention, can use resistant to elevated temperatures base resin material, the material of the operation of 1000 ℃ of those abilities for example obtains the resistive element of the very high-temperature of conductive loaded resin-based materials.
In this example, element 12 is a U-shaped, thus electric current I
HeatFrom power supply V
Heat14 flow through top lead/terminal and bottom lead/terminals of flowing through are returned.Work as electric current I
HeatDuring conduction, according to I
2R, element 12 produces heat.Since the heat conductivility of this conductive loaded resin-based materials excellence, this I
2The thermal energy conduction of R is to the outer surface of this element.So depend on application and the environmental condition of putting into element 12, these heat energy can shift from element 12 by conduction, convection current or radiation.In this example, element 12 uses direct currents (DC), yet, when element 12 by effective supply lines energy supply for example in dwelling house or industry when installing, also can easily use alternating current (AC).
Cross-sectional view is shown in the lattice structure 16 of the network of conducting fibre in the base resin and/or powder among Fig. 1 a, and conducting fibre and/or powder network 16 be the surface of representation element 12 also, but for easy diagram, not shown in the top view.Heating element of the present invention 12 shown in Fig. 1 a does not have external insulation layer, that is to say, the object on element 12 surfaces or fluid could directly contact and become electric loop with conductive material a part is not in most of the cases wished so.Therefore, electrical insulating material 18 and 20 can be formed on the conductive loaded resin-based materials 16, and promptly in second cross section 17, this electrical insulating material 18 and 20 can comprise having big thermal conductivity or have little thermally conductive materials.Under thermal-radiating situation, this is broken off edge material 18 and 20 and can comprise and selecting for use to have the material of high electromagnetic energy carry-over factor under specific wavelength.Selectively, during as if the warm pad of these heating element 12 conducts, help so forming top side electrical insulator 20 with thermally conductive materials, the heat of element 12 generations conducts to the object that sits on cushions like this.In this case, bottom side electrical insulator 18 can comprise not only possessing electric insulation but also possess heat-insulating material, and the heat of element 12 generations can not lose on downward direction like this.Selectively, the electric insulation layer 20 of top side and bottom side and 18 can comprise identical materials.
Electrical insulating material 18 and 20 includes, but are not limited to high-temperature resin sill, metal oxide, makrolon material, pottery and mica.Electrical insulating material 18 and 20 can be used by infusion process, spraying, coating, plating, covering mold moulding, extrusion molding, application binding agent with class methods.In second cross section 17, electrical insulating material 18 and 20 is the horizontal surface of cladding element 12 each lead-in wire only.Selectively, can cover the whole surf zone of this conductive loaded resin base heating element 16 by the electric insulation layer shown in the 3rd cross section 19 22.Between the lead-in wire of heating element 12, this layer can be with or without bridge joint interval 13.If this electric insulation layer 22 has bridge joint interval 13, then this electric insulation layer 22 can increase the mechanical strength and the hot surface area of this heating element 12.
As another optional characteristic, shown in the 4th and the 5th cross section 21 and 23, can on the conductive loaded resin-based materials surface, form metal level 24.In the 4th cross section 21, metal level 24 directly is formed on the conductive loaded resin-based materials 16.In the 5th cross section 23, electric insulation layer 25 at first is formed on the conductive loaded resin-based materials, forms metal level 27 again.The metal level 24 or 27 that appends to heating element 12 has changed electricity, heat, vision and the surface characteristics of the composite construction that obtains.If this metal level 24 directly is formed on this conductive loaded resin-based materials 16, then metal level 24 can be by electroplating or coating formation.If the formation method is metal plating, then the resin-based structural material of this conductive loaded resin-based materials 24 should metal plating.The available metal layer is electroplated very many fluoropolymer resins, and for example, GEPlastics, SUPEC, VALOX, ULTEM, CYCOLAC, UGIKRAL, STYRON, CYCOLOY are some resin-based materials that can use metal plating.Metal level 24 can form by for example plating or physical vapor deposition.Similarly, if resin-based materials is used as the electrical insulating material 25 of the 5th cross section 23, but then resin-based materials 25 is preferably metal plating as mentioned above.Unshowned other selected embodiment comprises a plurality of insulating barriers, imbeds conductor and/or other structure in conductive loaded resin-based materials 16 or electric insulation layer 18,20,22 and 25, and/or imbed electric insulation layer in conductive loaded resin base member 12.
Referring now to Fig. 7, be the diagram of second preferred embodiment 100 of the present invention.According to the present invention, stratie 100 is formed by conductive loaded resin-based materials, element 100 has the spirality of outer terminal 105 of band and interior terminal 106, and this layout is beneficial to the big otherwise planar surface area that forms by conduction, convection current or radiant transfer heat especially.Shown in cross section, conductive loaded resin base heating element 104 is preferably and wraps in electrical insulating material 108 and 112, for example, the spirality style of conductive loaded resin-based materials can cover mold and be molded on the electric insulation bottom 108, then, electric insulation layer 112 films can be by spraying, flood or being formed on the spirality style 104 with class methods.This top layer 112 provides a dielectric working surface, thereby conducts to anyly with surface 112 during to the object that contacts from element 110 when heat, and this top layer 112 has prevented electric shock.
This helical element 100 has shown heating properties very fast, and is beneficial to the application such as electric hot plate and electric stove mouth (cooktops) especially.By select the pliability base resin in conductive loaded resin-based materials 104 and pliability resin-based insulator 108 and 112, this helical element 100 can form the pliability material.In this case, this helical element 100 can be crooked, and it directly contacts nonplanar surface therefore to be particularly conducive to application.This helical element 100 puts on object by bonding or other mechanical maintenance method, and non-like this horizontal application becomes possibility.For example, this helical element 100 can be used for computer display or other electric equipment of operating under the low-down temperature of aerospace applications.This helical element 100 can be used for mirror in vehicle is used the back side is with defrosting and defogging, or prevents steam in bathroom/indicating device is used.Spirality style conductive loaded resin base heating element 100 remains within the spirit of the present invention can multiple shifting gears.Though illustrate foursquare style, can use the periphery and the similar arbitrary shape that comprise circle, ellipse, polygon, three-dimensional.
Referring now to Fig. 8 a, be the diagram of the 3rd preferred embodiment 120 of the present invention.In this case, illustrate heated seat 120.According to the present invention, stratie 124 and 130 is imbedded in chair or the seating systems 120, and lower heater 124 is imbedded in the lower position 121 of seating systems 120, and backside heaters 130 is imbedded in the back 123 of seating systems 120.Selectively, only use lower heater 124 or backside heaters 130, or dispose single heating element, this element extends through lower position 121 and back 123.According to the present invention, heating element 124 and 130 comprises conductive loaded resin-based materials.This element 124 and 130 can be a spirality style as shown in Figure 7, or uses the alternately style shown in Fig. 8 a.Selectively, can use shown in Fig. 8 b not with lines or the lead-in wire style even pad.Heating element 124 and 130 is as mentioned above by electric insulation.
By making up heating element from the conduction loaded resin-based materials, there are many current paths in the micron conducting fibre in material and/or the network of powder, therefore, this heating element 124 and 130 has high reliability aspect machinery and the electric fatigue.By with the relatively discovery of the conventional heated seat that uses coil or nichrome line, low seat and the continuous deflection of seat back have caused the mechanical fatigue of nichrome element, and cause breakage.Because formerly technology is based on single-wire for these, therefore any breakage all can cause forming open circuit and make the heater shut-down operation.Heating element 124 of the present invention and 130 provides many current paths inherently, thereby has improved reliability.Even its part fracture, said elements still can continuous firing.In addition, the pliability of this base resin has absorbed the deflection energy that the motion because of the user causes, thereby has improved reliability.
Each element 124 and 130 all is connected to the electric wire 126 and 128 or 132 and 134 of a pair of supplying energy.The device and the loop of unshowned temperature sensor and control temperature, can be used to provides comfortable heating for the seat user.The seat heater of this class especially is beneficial in the winter of cold and uses for the vehicle of driving over a long distance that can only accept low circulation.In addition, Re seat is beneficial to air travel, office application, recreation vehicle, the bed of hospital, and furniture.
Referring now to Fig. 8 b, be the diagram of another embodiment 139 of seat heating element.In this case, this seat/back heating element 139 is divided into top 140 and bottom 141, and according to the present invention, top and bottom 140 and 141 all comprise conductive loaded resin-based materials.Intermediate insulating layer 142 is with top 140 and bottom 141 electric insulations, and like this, this electrical connection 145 and 146 can be made the single end of heating element 139.The conductivity short fiber is passed through in top and bottom 140 and 141, the conductivity electric wire, or conductivity yarn 143 is electrically connected in the opposite end.
Referring now to Fig. 9, be the diagram of the 4th preferred embodiment 150 of the present invention, illustrate heating window 150.As under the situation of the mirror that heats, window is heated to prevent mist, steam or to freeze.Yet different with mirror is that the heating means that must dispose window are to avoid interference the transmission of light from window.The previous trial that the heating window is provided perhaps is applied to transparent conductivity tin indium oxide (ITO) film on the window for using the current supply circuit or the grid of the very thin metal cords in the clear films on being pasted on window for example.In the present invention, conductive loaded resin-based materials 156 is at first directly linked to each other with transparent panel 152, or be laminated in this case between two window panels (glass) 152 and 154.The base resin of conductive loaded resin-based materials 156 comprises material transparent, and micron conducting fibre and/or powder are opaque.Yet mixed uniformly small size micron conducting fibre and/or powder make sight line pass this conductive loaded resin base plane 156 fully without barrier in conjunction with the doping density of thin choosing in this base resin.This panel component 156 is electrically connected in relative end 158 and 160 places, and can be connected to vehicle battery power supply or AC power supplies.For easy manufacturing, this heating element 156 is extruded into thin slice.This window heater 156 helps the application in the scope of the control panel that comprises information demonstration, military vehicle, naval's flight-deck equipment, jumbo and farm equipment, periscope and offshore rehearsal platform.
Referring now to Figure 10, be the diagram of the 5th preferred embodiment 170 of the present invention, illustrate the mirror 170 of heating.This heated mirror 170 comprises the mirror assembly 170 with conductive loaded resin base heating element 174, and this element contacts with the dorsal part of reflecting plate 172.As shown in the cross section, the mold moulding in mirror outer cover 176 of reflecting plate 172 and heating element 174.Heating element injection moulding easily is needed definite size and dimension.Electric wire 178 and 180 is connected to power supply with heating element 174, and is not shown.Do not need insulating barrier by ambroin and minute surface (glass) heating element 174 of selecting the mold moulding.Shown a kind of rearview mirror 170, for example be installed on the motor vehicle usually.Yet the present invention also is used for outside vehicle mirror effectively.In addition, this conductive loaded resin base heating element can be applied to the dorsal part of bathroom/indicating device mirror, to prevent mist formation or steam.
Referring now to Figure 11, be the diagram of the 6th preferred embodiment of the present invention.According to the present invention, formed radiation floor heater 200 in this embodiment, with respect to the general forced air heating system that is installed in many families, the radiation floor heating system provides some unique advantages.By being floor heating, improved in the room sense temperature in the bathroom, ornamental slab for paving the floor ground especially, in addition, also realized the even heating in room, at last, do not come heat rooms/house owing to this system does not rely on air movement (convection current), thereby eliminated the problem of air pollution and filtration yet.General radiation floor heating system uses the metal cords loop as heating element.According to the present invention, the preferred embodiment of heating element 208 comprises conductive loaded resin-based materials.Can pass through for example extrusion molding conductive loaded resin-based materials thin slice, and loop structure is embossed on this sheet, form heating element 208 with successive loops structure 200.
The heating element 208 of conductive material is surrounded by electrical insulating material 222.Heating element 200 is layered on the floor surface 204, for example the horizontal material of concrete base of concrete floor or covering timber floor.Selectable net 206 can be connected to heating element 200 mechanical stability to be provided and to strengthen the mud 210 that applies.The mud or the mortar that apply overflow the ground that is used to lay ceramic tile 212 with selectable net with generation from heating element 200.This floor of the present invention heating element 200 especially is beneficial to the bathroom and the corner of dwelling house.
Referring now to Figure 12, for the diagram of the 7th preferred embodiment of the present invention, according to the present invention, in this embodiment, heating tape 230 is formed by conductive loaded resin-based materials.Heating tape 230 is used to fluid line 236 to provide localized heating to freeze preventing.Cold water pipes 236 generally is applied in the groove crack or garage that dwelling house supply lines or water pipe etc. pass through.General heating tape is formed by the metal cords that embeds rubber.According to the present invention, heating tape 230 preferred embodiments comprise conductive loaded resin base heating element 232 and 234 and terminal band 238.Terminal band 238 relatively links to each other with 234 with heating element 232 in the end with 230 with power line, and in addition, heating element 232 and 234 is by outer insulator 239 electric insulations.Heating element 232 and 234 is formed by the pliability base resin.Insulating barrier 239 is also formed by the pliability resin.A kind of typical manufacture process is at first by extrusion molding formation conductive loaded resin base heating element 232 and 234, insulating barrier 239 to be extruded covered this heating element 232 and 234 then.
Referring now to Figure 13,,, utilize conductive loaded resin base heating element to form cartridge heater device 250 according to the present invention for the diagram of the 8th preferred embodiment of the present invention.In the art, the cartridge heater device is used to needs the limited operation zone of sealing thermal control that localized heating is provided.The application of many commercial and industrials, for example compressor crankcase heating, photocopier, mould, food processing, plastic mo(u)lding, wax jar, and similar application have all used cartridge heater.The nichrome electric wire of general cartridge heater utilization insulation is as heating element, and the element that this has twined wrapped in the metal shell of sealing.According to the present invention, the preferred embodiment of cartridge heater device 250 is shown in the conductive loaded resin base heating element 252a and 252b that have insulating barrier center 260 and external insulation layer 262.In typical cartridge heater device, heating element 252 can be around central insulator 260 injection mouldings.Metal cords 256 links to each other this cartridge heater device with 258 with power supply, not shown.This heating element is a U-shaped, makes crown member lead-in wire 252a and base member lead-in wire 252b link to each other in the end with 258 with respect to power lug 256.If necessary, can optionally the metal level (not shown) be plated on the outside of cartridge heater device 250 to change hot property.
Referring now to Figure 14, be the diagram of the 9th preferred embodiment of the present invention, illustrate a kind of immersion heater device 270.The immersion heater device is used for heating fluid, and immersion heater is fit into storage cistern usually, adds thermal control accurately for the fluid in the storage cistern provides.The nichrome heating electric wire that general immersion heater utilization is encapsulated into the insulation of metal tube hermetically forms.According to the present invention, the preferred embodiment of immersion heater device 270 is shown in the conductive loaded resin base resistive element 276 in being sealed in electric insulation and liquid-tight resin-based cover 278.In this embodiment, power terminal links to each other at gas thread terminal 271 places.Article one, electric wire links to each other with the terminal 271 of resistive element 276, and another electric wire links to each other with 274 with the conductor 272 of the insulation of passing resistive element 276.At an end relative with screw thread terminal 271, the metal choke valve end cap (triple valve) 282 that embeds insulating resin sill 280 is used for center conductor 272 is connected to conductive loaded resin-based materials 276 to finish the heater loop.Utilize this technology, this stratie cross section as shown in the cross section, can be shaped to random length by extrusion molding and form, and cutting forms the specific dimensions of immersion heater 270 then.
Referring now to Figure 15, be the diagram of the tenth preferred embodiment of the present invention, show a kind of flange-cooled strip heater device 300.Flange-cooled strip heater device is used in baking oven and storing storehouse heated air.General flange-cooled strip heater utilization is encapsulated into the nichrome heating electric wire of the insulation of metal housing, and uses metal fin with the heat transferred air.According to the present invention, the preferred embodiment of flange-cooled strip heater device 300 is shown in the conductive loaded resin base resistive element 304 that is encapsulated into electric insulation layer 310.Resistive element 304 is the single band of conductive loaded resin-based materials, and this material extends to another embedding terminal 316 from embedding terminal 314.Outer cover 308 resistive element 304 electricity are internally isolated, yet the heat that element 304 produces is easy to be delivered to outer cover 308, and at this, heat is delivered in the air by the big surf zone of fin 318.Every fin 320 is separated by interval 322.Additional fin can be formed at the bottom side of outer cover 308, and outer cover 308 can comprise stamped metal, yet, as an optional characteristic, according to the present invention, outer cover 308 can comprise conductive loaded resin-based materials, and this material has shown excellent heat conductivility.The method for optimizing that forms flange-cooled strip heater device 300 is formed on the resistive element 304 of injection moulding for insulating barrier 310 is covered mold, then, outer cover 308 is covered mold be formed on insulator-resistive element accessory 304 and 310.
Referring now to Figure 16, be the diagram of the 11 preferred embodiment of the present invention, show a kind of pliability heater 330.The pliability heater can be used for providing the multiple application of localized heating difformity and size object, and the pliability heater is used for, and for example keeps suitable operating temperature for electronic unit in ultra-low temperature surroundings such as aviation.General pliability heater comprises the etching metal thin slice that wraps into insulator.According to the present invention, the preferred embodiment of pliability heater 330 interweaves shown in the conductive loaded resin base stratie 332 in loop as formation.Electric wire 336 and 338 is wrapped in the terminal of heating element 332 so that power supply to be provided, and stratie 332 is wrapped in the electric insulation layer 334.Preferably, electric insulation layer 334 comprises resin-based materials, more preferably, comprises the base resin identical materials with resistive element 332.Pliability heater 330 links to each other closely with heated object, in this case, forms complete loop apparatus 342 and 340.Can use adhesive to guarantee continuing connection between heater 330 and the object 342.Pliability heater 330 can be by for example with resistive element 332 injection mouldings of mixed uniformly conductive loaded resin-based materials, and cover the mold moulding thereon or be coated with insulating layer coating 334 and form.
Referring now to Figure 17, be the diagram of the 12 preferred embodiment of the present invention, show a kind of band shape or bar heater.Bar heater 350 is used for providing the localized heating of fluid of pressure-bearing pipe 354 to prevent to freeze or in the viscosity of multiple application control fluid 360.General bar heater comprises the nichrome electric wire that wraps into the insulation in the becket that twines around pipe.According to the present invention, the preferred embodiment of bar heater 350 is shown in the conductive loaded resin base stratie 352 that wraps into bar electrical insulating material 353 and 362.Terminal electric wire 356 and 358 each place, end around it is wrapped in the stratie 352 so that power supply to be provided.Bar heater assembly 350 can be by for example forming mixed uniformly conductive loaded resin-based materials injection moulding.By dipping or coating, forming insulating barrier 353 and 362 then, also can be simple layer.As another preferred embodiment, by the pliability resin-based materials of selecting to be used as the pliability base resin of conductive loaded resin-based materials and being used as insulating barrier 353 and 362, this heater can be made fully flexible to allow snap-on (" snap-on ") to fasten.
Referring now to Figure 18, be the diagram of the 13 preferred embodiment of the present invention, show a kind of heating tube device 370 of injection moulding.The heating tube device is used for the fluid by pipe or pipeline transmission, to prevent viscosity icing or control fluid 378 in multiple application.According to the present invention, the preferred embodiment of the heating tube device 370 of injection moulding is shown in the conductive loaded resin base stratie 374 that wraps into electrical insulating material shell 372.These device 370 preferred at first mold moulding conductive loaded resin base heating elements 374 that pass through cover mold shell molds 372 then and form outside resin-based materials.Electric terminals 376 is embedded into to come in the resistive element 374 provides power supply for this element.
Referring now to Figure 19, be the diagram of the 14 preferred embodiment according to the present invention, show a kind of heating tube device 400.Pipe heating device is used to heat the liquid that transmits in pipe or pipeline, to prevent viscosity icing or control fluid 414 in multiple application.General pipe heater comprises the metal cords heating element that wraps in the rubber tube.The preferred embodiment of pipe heating device 400 comprises transfer tube, rubber tube 401 that for example can transmitting fluid 414, and conductive loaded resin base heating element 402 surrounds these transfer tubes 401.Electric insulation layer 409 surrounds this heating element 402 isolates so that electricity to be provided.
In the simplest shape, heating element can contact in each end of its length direction simply by exposing conductive loaded resin-based materials 402, carries out mechanical clamp or pin connection then.Then flow through the length of this heating tube 400 by the electric current of power supply supply, not shown.In order to promote to finish the loop, also the electric wire 416 of insulation can be embedded in the conductive loaded resin-based materials 402, this electric wire 416 utilizes clamp/engaging mechanism 410 and 412 as shown in the figure to promote finishing of loop.In this embodiment, clamp/engaging mechanism 410 and 412 comprises metal bond device 412, and this connector passes the electric wire 416 of insulation, and is embedded in the resistive element 402, thereby at one end electric wire 416 is linked to each other with resistive element 402.In the opposite end, clamp/engaging mechanism 410 and 412 only is used to connect resistive element 402.Preferably, the base resin of conductive loaded resin-based materials 402 and insulating barrier 409 includes the pliability material.Selectively, transporting hose 401 can comprise the base resin identical materials with conductive loaded resin-based materials 402.The heating tube device 400 of this embodiment can draw resistive element 402 extruders with transporting hose 401 and the electric wire 416 that insulate then by for example in transporting hose 401 extrusion molding moulding place co-extrusion modlings.
Referring now to Figure 20 to 22, be the diagram of the 15 preferred embodiment of the present invention, show tubular heating device.Tubular heating device is as hot-water heater, kitchen heating resistance pad, baking oven, and is used for heating fluid and other material in the similar application.General tubular heater comprises the metal cords heating element that is encapsulated into the insulation in the metal tube.Especially with reference to Figure 20, show preferred embodiment now according to tubular heating device 450 of the present invention.Tubular heating device 450 comprises the conductive loaded resin base center 452 that is surrounded by electric insulation layer 454, and this tubular heating device 450 forms the loop shape that will use, for example, is applied in the heater of food or water.Contact terminal 456 provides electrical connection for each end of the resistive element in the tubular heating device 450 452.This tubular heating device can cut and this element of extruding that is shaped by for example extrusion molding moulding flexible conducting loaded resin base member 452, applies this element with insulating barrier 454 then.Selectively, tubular heating element 452 can form by injection moulding.Especially with reference to Figure 21, the upper and lower tubular heating element 464 and the 468 hot-water heater devices 460 that have conductive loaded resin-based materials are shown.
Especially with reference to Figure 22, according to the present invention, this tubular heating device is applied to heat towel rack 480 now.Towel bar 483 is formed by conductive loaded resin base heating element 482, and heating element 482 is coated by electric insulation layer 484 once more.In addition, outer layer metal layer 486 can apply or be gold-plated on insulating barrier 484, to obtain metal appearance.Each heating pole 483 is held support 488 and fixes, and this bar 483 is connected to control unit 489 by electric wire 487, and this control unit is regulated the electric current of the bar 483 of flowing through with the control temperature.Tubulose heating pole 483 can form by for example extrusion molding.
Conductive loaded resin-based materials described here generally comprises the micron powder of conductive particle and/or combines with mixed uniformly micrometer fibers in base resin matrix.Fig. 2 shows the viewgraph of cross-section of an example of conductive loaded resin-based materials 32, has conductive particle powder 34 in the base resin matrix 30 of this conductive loaded resin-based materials 32.The diameter D of pulverous in this example conductive particle 34 is between about 3 and 12 microns.
Fig. 3 shows the viewgraph of cross-section of an example of conductive loaded resin-based materials 36, has conductive fibers 38 in the base resin matrix 30 of this conductive loaded resin-based materials 36.Conductive fibers 38 has big diameter between 3 and 12 microns, and generally 10 microns scope, perhaps between about 8 and 12 microns, and length is between 2 and 14 millimeters.Conductor as these conductive particles 34 or conductive fibers 38 can be stainless steel, nickel, copper, silver, or other suitable metal or conducting fibre, or above combination.These conductive particles and or fiber evenly mixing in base resin.Just as mentioned above, this conductive loaded resin-based materials have greatly about 5 and 25ohm between resistance value, can be by changing the resistance value that doping parameter and/or resin choice obtain other.For obtaining this resistance value, the part by weight of conductor material, in this example, conductive particle 34 or conductive fibers 38 between about 0.20 and 0.40, and are preferably about 0.30 with respect to the weight of base resin matrix 30.With respect to the part by weight of base resin is 0.30 8-11 micron diameter, the stainless steel fibre of 4-6mm length can produce very high in any EMF spectrum effective conduction parameter.Referring now to Fig. 4, the diagram another preferred embodiment of the present invention, wherein conductive material comprises the combination of electroconductive powder 34 and micron conducting fibre 38, it evenly mixes in resin basis 30 in the mold forming process.
Referring now to Fig. 5 a and 5b, illustrate the preferred compositions of this conductive loaded resin-based materials.This conductive loaded resin-based materials can form fiber or fabric, and above-mentioned then fiber or fabric weaving or one-tenth net are conductive fabric.This conductive loaded resin-based materials forms the yarn of weaving as shown in the figure.Fig. 5 a illustrates conductive fabric 42, and wherein fiber is knitted in the control of two- dimensional braided 46 and 50 of fiber or textile and is in the same place.Fig. 5 b diagram conductive fabric 42 ', wherein, this fiber forms netted arrangement.In this netted arrangement, the continuous yarn of one or more of conductive fabric is nested to be form arbitrarily.Final conductive fabric or textile 42 are seen Fig. 5 a and 42 ', see Fig. 5 b, can make very thin, thick, hard, pliability or solid form.
Similarly, conductivity but the material of cloth specimen can utilize weaving or become net micron stainless steel fibre or other a micron conducting fibre forms.Also can the interlayer laminated material in one layer or more of these weavings or conductive fabric into the net is polyethylene, the special not resin-based materials of jade for asking rain, Kai Fula or any other hope for example.This then conductive fabric can cut into desirable shape and size.
The heater that is formed by conductive loaded resin-based materials can be shaped or the mold moulding with several different methods, comprises injection method moulding, extrusion molding or chemical induction moulding or shaping.Fig. 6 a represents the rough schematic view of injection method moulding, has shown the lower position 54 and the position, top 58 of mould 50.Conductive loaded hybrid resin sill injects mould cavities 64 by injecting opening 60, solidifies mixed uniformly conductive material by thermal response then, separates then or the separately position, top 58 of this mould and lower position 54, and shifts out this heater.
Fig. 6 b represents to utilize extrusion molding to form the rough schematic view of the extruder 70 of heater.Conductive loaded resin-based materials is positioned in the feed hopper 80 of extruding unit 74, a piston, screw rod, forcing press or other parts 78 squeeze out conductive loaded resin-based materials hot melt or that chemical induction is handled by extruding opening 82 then, make this be configured as desirable shape through the conductive loaded resin-based materials that hot melt is handled or chemical induction is handled.Fully solidify by chemical reaction or thermal response then, make the abundant hardening of this conductive loaded resin-based materials or become pliable and tough state with standby.
Summarize advantages more of the present invention now.Obtain effective heater, obtained forming the method for heater.This heater is by conductive loaded resin-based materials mold moulding.Performance by the heater of conductive loaded resin-based materials moulding can be selected based on the conductive material that mixes in resin-based materials.Performance by the heater of conductive loaded resin-based materials mold moulding can be selected based on the performance of selected resin-based materials.The method of making heater from conductive loaded resin-based materials is different because of different material shape.Obtained a series of heater of the heating element of band conductive loaded resin-based materials.
Shown in a preferred embodiment, new method of the present invention and device provide effectively and the selection that can make with respect to prior art.
Yet the present invention has carried out specific diagram and description with reference to its preferred embodiment, and those skilled in the art can know, under the situation that does not deviate from the spirit and scope of the present invention, can change form and details.
Claims (71)
1, a kind of heater comprises:
Heating element, this element is included in the conductive loaded resin-based materials that contains conductive material in the base resin matrix;
First terminal, this first terminal connects at first end of described heating element; With
Second terminal, this second terminal connects at second end of described heating element.
2, device according to claim 1 is characterized in that: described conductive material with respect to the part by weight of described resinous substrates between about 0.20 and about 0.40.
3, device according to claim 1 is characterized in that: described conductive material comprises metal dust.
4, device according to claim 3 is characterized in that: described metal dust is nickel, copper or silver.
5, device according to claim 3 is characterized in that: described metal dust is the non-conductive material of the band coat of metal.
6, device according to claim 5 is characterized in that: the described coat of metal is nickel, copper or silver.
7, device according to claim 3 is characterized in that: the diameter of described metal dust is between about 3 μ m and about 12 μ m.
8, device according to claim 1 is characterized in that: described conductive material comprises non-metal powder.
9, device according to claim 8 is characterized in that: described non-metal powder is carbon, graphite or amido material.
10, device according to claim 1 is characterized in that: described conductive material comprises the combination of metal dust and non-metal powder.
11, device according to claim 1 is characterized in that: described conductive material comprises a micron conducting fibre.
12, device according to claim 11 is characterized in that: described micron conducting fibre is nickel-coated carbon fibers, stainless steel fibre, copper fiber, silver-colored fiber or above-mentioned combination.
13, device according to claim 11 is characterized in that: the diameter of described micron conducting fibre is between about 3 μ m and about 12 μ m, and length is approximately between 2mm and the about 14mm.
14, device according to claim 1 is characterized in that: described conductive material comprises the combination of conduction green powder and conducting fibre.
15, device according to claim 1 is characterized in that: described device also comprises the electric insulation layer that coats described heating element.
16, device according to claim 15 is characterized in that: described electric insulation layer is a high-termal conductivity.
17, device according to claim 15 is characterized in that: described electric insulation layer is a resin-based materials.
18, device according to claim 15 is characterized in that: described electric insulation layer is a metal oxide.
19, device according to claim 15 is characterized in that: described electric insulation layer is pottery.
20, device according to claim 15 is characterized in that: described electric insulation layer is a makrolon material.
21, device according to claim 15 is characterized in that: described electric insulation layer is the mica-based material.
22, device according to claim 15 is characterized in that: described heating element and described electric insulation layer are flexual.
23, device according to claim 15 is characterized in that: described device also comprises the electric wire that embeds described electric insulation layer.
24, device according to claim 15 is characterized in that: described base resin and described electric insulation layer comprise fire proofing.
25, device according to claim 1 is characterized in that: described device also comprises the metal level that covers described heating element.
26, device according to claim 1 is characterized in that: described heating element comprises a smooth pad.
27, device according to claim 26 is characterized in that: described smooth pad is a helical pattern.
28, device according to claim 1 is characterized in that: described heater is embedded in the seat apparatus.
29, device according to claim 1 is characterized in that: described heater is in turn laminated on the transparent panel.
30, device according to claim 29 is characterized in that: described base resin is transparent.
31, device according to claim 1 is characterized in that: described heater is attached on the mirror.
32, device according to claim 1 is characterized in that: described heater is embedded in the floor system.
33, device according to claim 1 is characterized in that: described heater is a cartridge heater.
34, device according to claim 1 is characterized in that: described heater also comprises a plurality of conductibility fin.
35, device according to claim 34 is characterized in that: described conductibility fin comprises conductive loaded resin-based materials.
36, device according to claim 1 is characterized in that: described heater is around the pipe combination.
37, device according to claim 1 is characterized in that: but described heater is the hollow tube or the pipeline of transmitting fluid.
38, device according to claim 1 is characterized in that: described heater is a round bar.
39, device according to claim 1 is characterized in that: described device also comprises the electric wire that embeds described heating element.
40, a kind of heater comprises:
Heating element, this element is included in the conductive loaded resin-based materials that comprises conductive material in the base resin matrix, and wherein said conductive material comprises the combination of electroconductive powder and conducting fibre;
Electric insulation layer, this electric insulation layer coats described heating element;
First terminal, this terminal connects at first end of described heating element; With
Second terminal, this terminal connects at second end of described heating element.
41, according to the described device of claim 40, it is characterized in that: described conductive material with respect to the part by weight of described resinous substrates between about 0.20 to about 0.40.
42, according to the described device of claim 40, it is characterized in that: described electroconductive powder comprises non-metal powder.
43, according to the described device of claim 42, it is characterized in that: described non-metal powder is carbon, graphite or amido material.
44, according to the described device of claim 40, it is characterized in that: described electroconductive powder comprises metal dust.
45, according to the described device of claim 44, it is characterized in that: described metal dust is nickel, copper or silver.
46, according to the described device of claim 44, it is characterized in that: described metal dust is the non-conductive material of the band coat of metal.
47, according to the described device of claim 46, it is characterized in that: the described coat of metal is nickel, copper or silver.
48, according to the described device of claim 44, it is characterized in that: the diameter of described metal dust is between about 3 μ m and about 12 μ m.
49, according to the described device of claim 40, it is characterized in that: described micron conducting fibre is nickel-coated carbon fibers, stainless steel fibre, copper fiber, silver-colored fiber or above-mentioned combination.
50, according to the described device of claim 40, it is characterized in that: the diameter of described micron conducting fibre is between about 3 μ m and about 12 μ m, and length is approximately between 2mm and the 14mm.
51, according to the described device of claim 40, it is characterized in that: described electric insulation layer is a resin-based materials.
52, according to the described device of claim 40, it is characterized in that: described electric insulation layer is a metal oxide.
53, according to the described device of claim 40, it is characterized in that: described electric insulation layer is pottery.
54, according to the described device of claim 40, it is characterized in that: described electric insulation layer is a makrolon material.
55, according to the described device of claim 40, it is characterized in that: described electric insulation layer is the mica-based material.
56, according to the described device of claim 40, it is characterized in that: described heating element and described electric insulation layer are flexual.
57, a kind of method that forms the heating element device, described method comprises:
A kind of conductive loaded resin-based materials that comprises conductive material in resinous substrates is provided; And
Described conductive loaded resin-based materials mold is shaped to a kind of heating element device.
58, according to the described method of claim 57, it is characterized in that: described conductive material with respect to the part by weight of described resinous substrates between about 0.20 and about 0.40.
59, according to the described method of claim 57, it is characterized in that: described conductive material comprises electroconductive powder.
60, according to the described method of claim 57, it is characterized in that: described conductive material comprises a micron conducting fibre.
61, according to the described method of claim 57, it is characterized in that: described conductive material comprises the combination of electroconductive powder and conducting fibre.
According to the described method of claim 57, it is characterized in that 62, described mold moulding comprises:
Described conductive loaded resin-based materials is injected mould;
Solidify described conductive loaded resin-based materials; And
Described heating element device is removed from described mould.
63, according to the described method of claim 62, it is characterized in that: described method also is included on the described heating element device and forms electric insulation layer.
64, according to the described method of claim 63, it is characterized in that: the step of described formation electric insulation layer comprises covering mold moulding.
65, according to the described method of claim 63, it is characterized in that: the step of described formation electric insulation layer comprises dipping, spraying or applies.
66, according to the described method of claim 62, it is characterized in that, described method also is included in forming electric insulation layer before the described conductive loaded resin-based materials injection mould, wherein described heating element device is covered mold and is molded on the described electric insulation layer.
67 according to the described method of claim 57, it is characterized in that, described mold moulding comprises:
With the described conductive loaded resin-based materials container of packing into;
By an outlet that is shaped described conductive loaded resin-based materials is extruded in described container; And
Solidify described conductive loaded resin-based materials to form described heating element device.
68, according to the described method of claim 67, it is characterized in that: described method also comprises punching press or grinds described conductive loaded resin-based materials.
69, according to the described method of claim 67, it is characterized in that: described method also is included on the described heating element device and forms electric insulation layer.
70, according to the described method of claim 69, it is characterized in that: the step of described formation electric insulation layer comprises the extrusion molding moulding.
71, according to the described method of claim 69, it is characterized in that: the step of described formation electric insulation layer comprises dipping, spraying or applies.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US46187703P | 2003-04-10 | 2003-04-10 | |
| US60/461,877 | 2003-04-10 | ||
| US47877403P | 2003-06-16 | 2003-06-16 | |
| US60/478,774 | 2003-06-16 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN1543264A true CN1543264A (en) | 2004-11-03 |
Family
ID=32872266
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CNA2004100387434A Pending CN1543264A (en) | 2003-04-10 | 2004-04-12 | Low cost heating devices manufactured from conductive loaded resin-based materials |
Country Status (5)
| Country | Link |
|---|---|
| EP (1) | EP1467598A2 (en) |
| JP (1) | JP2004319493A (en) |
| KR (1) | KR20040089521A (en) |
| CN (1) | CN1543264A (en) |
| CA (1) | CA2464923A1 (en) |
Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101946558B (en) * | 2008-02-20 | 2013-11-06 | 住友化学株式会社 | Heater, resin molding apparatus, resin molding method and resin molded body |
| CN105357781A (en) * | 2015-11-18 | 2016-02-24 | 山东大学 | Carbon-fiber braiding radiation heating band with reflection structure and preparation method thereof |
| CN106166844A (en) * | 2016-07-01 | 2016-11-30 | 山东省科学院能源研究所 | Fluoroplastics heat exchange structure |
| CN110752433A (en) * | 2018-07-23 | 2020-02-04 | Ａｇｃ株式会社 | Vehicle window glass and vehicle window glass device |
| CN111936215A (en) * | 2018-03-29 | 2020-11-13 | 沃特世科技公司 | Thermal pad and column stabilizer assembly |
| CN113455102A (en) * | 2019-02-20 | 2021-09-28 | 株式会社巴川制纸所 | Sheet heater |
| CN114532634A (en) * | 2016-01-26 | 2022-05-27 | 黑达乐格瑞菲工业有限公司 | Heatable garment, fabric for such a garment and method of manufacture |
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| EP1688969A3 (en) * | 2005-02-02 | 2006-09-13 | Behr GmbH & Co. KG | Serial resistor |
| KR100797094B1 (en) * | 2006-09-29 | 2008-01-22 | 한국기계연구원 | Trasparent heater and fabricating method thereof |
| DE102011017811A1 (en) * | 2011-04-29 | 2012-10-31 | Evonik Degussa Gmbh | Temperable pipeline for offshore applications |
| DE102011081831A1 (en) * | 2011-08-30 | 2013-02-28 | Webasto Ag | Electric heating unit, heating apparatus for a vehicle and method of manufacturing a heating unit |
| JP2015026422A (en) * | 2013-07-24 | 2015-02-05 | 日産自動車株式会社 | Conductive cloth |
| WO2016113633A1 (en) | 2015-01-12 | 2016-07-21 | Laminaheat Holding Ltd. | Fabric heating element |
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| KR102044197B1 (en) * | 2018-05-14 | 2019-11-13 | (주)다인스 | Heating element for seat |
| USD911038S1 (en) | 2019-10-11 | 2021-02-23 | Laminaheat Holding Ltd. | Heating element sheet having perforations |
-
2004
- 2004-04-08 CA CA002464923A patent/CA2464923A1/en not_active Abandoned
- 2004-04-09 KR KR1020040024399A patent/KR20040089521A/en not_active Application Discontinuation
- 2004-04-09 EP EP04368026A patent/EP1467598A2/en not_active Withdrawn
- 2004-04-12 JP JP2004117035A patent/JP2004319493A/en active Pending
- 2004-04-12 CN CNA2004100387434A patent/CN1543264A/en active Pending
Cited By (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101946558B (en) * | 2008-02-20 | 2013-11-06 | 住友化学株式会社 | Heater, resin molding apparatus, resin molding method and resin molded body |
| US10131081B2 (en) | 2008-02-20 | 2018-11-20 | Sumitomo Chemical Company, Limited | Heater, resin molding apparatus, resin molding method and resin molded body |
| CN105357781A (en) * | 2015-11-18 | 2016-02-24 | 山东大学 | Carbon-fiber braiding radiation heating band with reflection structure and preparation method thereof |
| CN105357781B (en) * | 2015-11-18 | 2018-03-02 | 山东大学 | A kind of carbon fiber braiding radiant heating band with catoptric arrangement and preparation method thereof |
| CN114532634A (en) * | 2016-01-26 | 2022-05-27 | 黑达乐格瑞菲工业有限公司 | Heatable garment, fabric for such a garment and method of manufacture |
| CN106166844A (en) * | 2016-07-01 | 2016-11-30 | 山东省科学院能源研究所 | Fluoroplastics heat exchange structure |
| CN106166844B (en) * | 2016-07-01 | 2018-11-20 | 山东省科学院能源研究所 | Fluoroplastics heat exchange structure |
| CN111936215A (en) * | 2018-03-29 | 2020-11-13 | 沃特世科技公司 | Thermal pad and column stabilizer assembly |
| CN110752433A (en) * | 2018-07-23 | 2020-02-04 | Ａｇｃ株式会社 | Vehicle window glass and vehicle window glass device |
| CN110752433B (en) * | 2018-07-23 | 2024-03-08 | Ａｇｃ株式会社 | Vehicle window glass and vehicle window glass device |
| CN113455102A (en) * | 2019-02-20 | 2021-09-28 | 株式会社巴川制纸所 | Sheet heater |
Also Published As
| Publication number | Publication date |
|---|---|
| CA2464923A1 (en) | 2004-10-10 |
| JP2004319493A (en) | 2004-11-11 |
| KR20040089521A (en) | 2004-10-21 |
| EP1467598A2 (en) | 2004-10-13 |
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