JP2011049162A - Composition for molding ptc sheet heating element, method for manufacturing ptc sheet heating element, and ptc sheet heating element - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a composition for molding a PTC sheet heating element which can generate heat with low power energy and has heat resistance and sufficient strength; and to provide a PTC sheet heating element formed by molding the composition. <P>SOLUTION: The composition for molding the PTC sheet heating element includes graphite, glass wool and/or rock wool, and water as a main component, or a polyamide resin is further included in the composition. Furthermore, in a method for manufacturing the PTC sheet heating element, a portion of the composition for molding the PTC sheet heating element is poured into an outer frame container 4, and the balance of the composition for molding the PTC sheet heating element is poured into the outer frame container after an electrode wire 3 is wired on a part where a portion of the composition is poured, and then, the composition is dried. Furthermore, the PTC sheet heating element 1 is manufactured with the manufacturing method, and the PTC sheet heating element 1 has a terminal part 2 for current conduction to be connected to the electrode wire 3. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a PTC planar heating element molding composition having a property that the heating element reacts to its own temperature to control the amount of electricity applied and to control the heating value, a method for producing a PTC planar heating element, and a PTC planar shape It relates to a heating element.

  There is known a PTC planar heating element having a property that the heating element reacts to the self-temperature to control the amount of energization to control the heating value. The PTC planar heating element has the property that the electrical resistance increases and the electricity hardly flows as the temperature of the heating element increases. When this PTC sheet heating element is used, for example, for floor heating, it reacts to the temperature rise due to the sunshine on the floor and the temperature rise in places where people are likely to sit and heat up. It is effective for energy saving. As a PTC sheet heating element molding composition having such excellent properties and a PTC sheet heating element using the composition, those containing raw paper shredded pulp material as a raw material are known (for example, special Open 2009-99329).

JP 2009-99329 A

  However, in the above-mentioned JP-A-2009-99329, since the waste paper shredded pulp material is included in the raw material, if the temperature of the heating element is increased by energization, the waste paper shredded pulp material in the raw material may ignite, It cannot be used after raising the temperature too high. Moreover, since the waste paper shredded pulp material in the raw material has no strength, it is necessary to use a special curing agent for increasing the strength of the entire heating element.

  In view of the above-mentioned problems, the present invention was created to solve the problems, and the object of the present invention is to generate heat with low power energy, and to have heat resistance. An object of the present invention is to provide a PTC sheet heating element molding composition having strength, a method for producing a PTC sheet heating element, and a PTC sheet heating element.

  In order to achieve the above object, the invention for forming a PTC planar heating element according to claim 1 comprises means containing graphite, glass wool or / and rock wool, and water as main components.

  Further, the invention of the composition for molding a PTC planar heating element according to claim 2 includes graphite, glass wool or / and rock wool, and water as main components, the blending composition is in a weight ratio, and graphite is 1. It consists of means consisting of 5% to 25% glass wool and / or rock wool and 50% to 100% water.

  The invention of the composition for molding a PTC sheet heating element according to claim 3 comprises means containing graphite, glass wool or / and rock wool, water, and a polyamide-based resin as main components.

  The invention of the composition for molding a PTC planar heating element according to claim 4 includes graphite, glass wool or / and rock wool, water, and a polyamide-based resin as main components, and the blending composition is in a weight ratio. The ratio of glass wool and / or rock wool is 5% to 25%, water is 50% to 100%, and polyamide-based resin is 5 to 40% with respect to a ratio of 1 graphite.

  Further, as a preferred embodiment of claims 1 to 4, the invention of claim 5 is characterized in that the graphite has an average particle size of 1 to 30 μm, and the invention of claim 6 uses glass wool as waste. In the invention of No. 7, waste is used for rock wool.

  An invention of a method for producing a PTC planar heating element according to claim 8 is the upper surface of the composition for molding a PCT planar heating element according to any one of claims 1 to 7 surrounded by a side circumferential surface and a bottom surface. Is partially poured into the open outer frame container, and after the electrode wire is wired on the partially poured portion, the remainder is poured, and then the unit is dried.

  The invention of the PTC planar heating element according to claim 9 is manufactured by the manufacturing method according to claim 8 and comprises means having a current-carrying terminal portion connected to the electrode wire.

According to the present invention comprising means for solving the problems, the following extremely beneficial effects can be obtained.
(1) Electric power of 100V to 200V is not required, and heat can be generated at a lower voltage, such as 5V to 12V.
(2) Glass wool is a glass fiber and has high heat resistance compared to the fibers of waste paper shredded pulp material, and uses glass wool, which has higher heat resistance than waste paper shredded pulp material, so the temperature of the heating element is set high. It becomes possible to do.
(3) Rock wool is an artificial mineral fiber that has higher heat resistance compared to the fibers of waste paper shredded pulp material, and uses heat-resistant rock wool as a raw material. Can be set high.
(4) By using the outer frame container, the use of a special curing agent for increasing the strength can be omitted, and the strength of the heating element can be increased without using the curing agent.
(5) Glass wool or rock wool waste, which has been difficult to dispose of up to now, can be used as a raw material, so that the waste can be used effectively and the raw material cost can be reduced.
(6) Moreover, when a polyamide-type resin is included, a PTC effect can be generated much more effectively. That is, the effect of preventing the temperature from rising above a certain temperature even when a high voltage is applied can be further enhanced. In this case, when the polyamide resin is a polyamide resin protective material, the strength of the heating element can be further increased.

It is an external appearance perspective view of the PTC planar heating element shape | molded in the rectangular parallelepiped state in which there is no outer frame container which shows the form for implementing this invention. It is an external appearance perspective view of the PTC planar heating element shape | molded in the cylindrical body of a state without the outer frame container which shows the form for implementing this invention. It is a plane sectional view of a PTC sheet heating element in the state where there is no outer frame container which shows a form for carrying out this invention. It is a perspective view of the outer frame container which shows the form for implementing this invention.

Hereinafter, the present invention will be described more specifically.
The composition for molding a PTC planar heating element of the present invention is as follows.
(I) Graphite.
(B) Glass wool or / and rock wool.
That is, when using glass wool alone, when using rock wool alone, and when using a mixture of glass wool and rock wool, there are three combinations.
(C) Water.
(D) Polyamide resin.
These (A) to (C) are contained as main components. Alternatively, in addition to these, (a) to (d) containing (d) are contained as main components. The main component includes this as an essential component and includes 90% or more of the total amount by weight.

  Graphite may be produced by various production methods, but the average particle size is in the range of 1 to 30 μm, and the most preferable particle size is 8 to 9 μm. When the average particle diameter is less than 1 μm or more than 30 μm, it is difficult to make the dispersion of the graphite uniform and the conductive heat generation uniform as a planar heating element. Here, the graphite includes artificial graphite in addition to natural graphite. Artificial graphite has properties of lower electrical resistance and higher strength than natural graphite. Therefore, when artificial graphite is used as graphite, the power energy cost of the PTC planar heating element can be reduced. The strength of the PTC planar heating element can be increased.

  Glass wool is a cotton-like material made of short glass fibers. It is used as a heat insulating material in addition to being used as a heat insulating material for buildings, and has excellent fire resistance. The heat resistance of the PTC sheet heating element can be increased, and the set temperature of the PTC sheet heating element can be increased. Moreover, since it has heat insulation, the PTC planar heating element containing this also has heat insulation, and is excellent in energy saving.

  Rock wool is an artificial mineral fiber that is produced by mixing lime with basalt, iron furnace slag, etc. and melting at high temperatures. It is used as a heat insulating material for buildings as well as glass wool. Moreover, since it is excellent also in fire resistance, the heat resistance of the PTC planar heating element can be increased by including this in the raw material, and the set temperature of the PTC planar heating element can be increased. Moreover, since it has heat insulation, the PTC planar heating element containing this also has heat insulation, and is excellent in energy saving.

In the molding composition, the PTC planar heating element in this invention has the following composition (b) and (c) with respect to the ratio of the weight ratio of the graphite and the ratio of 1, and (b) to (b) D) There may be cases.
(B) 5% to 25% glass wool or / and rock wool, that is, 5% to 25% glass wool, 5% to 25% rock wool, 5% mixed glass wool and rock wool In the case of ˜25%, there are three types, and a preferable ratio among them is glass wool and / or rock wool 10%, that is, glass wool 10%, rock wool 10%, glass wool and rock wool This is the case where 10% is mixed.
(C) Water is 50% to 100%, and among these, water is preferably 90%.
(D) The polyamide-based resin is 5 to 40%. When the temperature of the heating element is kept low, for example, when it is desired to keep it at 30 ° C., the amount used is increased to about 40%, for example. On the other hand, when the temperature of the heating element is kept high, for example, when it is desired to keep it at 70 ° C., the amount used is reduced to about 5%, for example. The amount of polyamide resin used is inversely proportional to the temperature at which the heating element is desired to be maintained. That is, the amount of use decreases when the temperature at which the heating element is to be maintained increases, and the amount of use increases when the temperature decreases.
For example, polyethylene beads are used as the polyamide-based resin, or a polyamide-based resin protective material is used particularly when it is necessary to increase the strength of the heating element.
The component ratio of the polyamide resin protective material is, for example, as follows.
Polyamide 15%
Ethanol 41%
Methanol 15%
npropanol 20.5%
8% water
Other 0.5%
By setting the blending ratio as described above, it is possible to reliably and stably obtain a PTC planar heating element having excellent strength and heat resistance and excellent heat generation characteristics with lower power energy.

  The composition for molding a PTC planar heating element according to the present invention facilitates release from a colorant, a dispersant, a binder, or a mold in an allowable range other than the above components. A release agent or the like is appropriately blended as necessary. The PTC sheet heating element is generally black due to graphite, but PTC sheet heating elements of various colors can be obtained by adding a colorant.

Next, molding of the PTC planar heating element of the above invention will be described below.
1 to 4 relate to a mode for carrying out the present invention, FIG. 1 is an external perspective view of a PTC sheet heating element formed into a rectangular parallelepiped, and FIG. 2 is a diagram of a PTC sheet heating element formed into a cylinder. FIG. 3 is an external perspective view, FIG. 3 is a plan sectional view of a PTC sheet heating element, and FIG. 4 is a perspective view of an outer frame container.

  Glass wool and / or rock wool and a part of the water to be used are put into a stirrer and stirred, and then graphite and the remaining water are added into the stirrer and stirred (in the case of Example-1). In the case of containing a polyamide-based resin, a part of the water to be used with glass wool and / or rock wool and the polyamide-based resin are stirred in a stirrer, and then graphite and the remaining water are put into the stirrer. In addition, stirring is carried out (in the case of Example-2). If necessary, a colorant, a dispersant, a binder, a release agent, and the like are appropriately added. By performing the stirring, the materials are uniformly mixed, and uneven heating effects and uneven strength can be prevented. The molding composition for the PTC planar heating element after stirring becomes a clay.

  The molding composition for the PTC planar heating element that has become clay-like is poured into the outer frame container 4. The outer frame container 4 used has, for example, a box-shaped lunch box shape in which, for example, four side surfaces and a bottom surface of the side peripheral surface are made of a thin metal plate and an upper surface is opened. An insertion hole 41 for the electrode wire 3 is formed in a part of the side surface of the outer frame container 4. In the case of pouring, about half of it is poured into the lunch box type outer frame container 4 and the two electrode wires 3 constituting the positive electrode and the negative electrode are inserted and projecting from the insertion hole 41 of the outer frame container 4 to the outside. 2 and the rest is poured and integrated with the molding composition of the PTC planar heating element 1. When the size of the outer frame container 4 is large, a plurality of electrode wires 3 and energizing terminal portions 2 constituting the positive electrode and the negative electrode are used.

  Thereafter, the composition for molding the PTC planar heating element is hardened in the outer frame container 4 by drying for a certain time. For example, forced drying using an electric furnace or the like has a drying time of about 12 hours. In natural drying, the drying time is about 10 to 14 days. The PTC sheet heating element 1 is obtained in which the natural drying is stronger than the forced drying. After solidifying, the PTC planar heating element 1 excellent in strength and heat resistance integrated with the outer frame container 4 is obtained.

As an example of use of the PTC sheet heating element 1 thus produced, the floor heating of the building is arranged under the floor, the condensation prevention is arranged on the wall, and it is also used for heating of the greenhouse. It is put in and used for the heat insulation of the water tank, and further, it is put in the bathtub and used for the heat insulation of the bath water.

  Glass wool: 1 kg and water: 1 liter were placed in a stirrer and stirred, and then graphite: 10 kg of average particle size 8.32 μm and the remaining water: 9 liters were added to the stirrer and stirred for about 30 minutes. As graphite, those shown in Table 1 below were used.

  After the stirring, the molding composition of the PTC planar heating element is poured into a mold having a size of, for example, 250 mm × 300 mm × 12 mm, and two electrode wires constituting a plus electrode and a minus electrode are inserted and the molding composition It was made to project outside from the end of the object to be a current-carrying terminal, and the rest was poured. A copper wire having a diameter of 2.5 mm was used as the electrode wire.

  Thereafter, this was put in an electric furnace and forcedly dried at a temperature of about 70 degrees for about 12 hours to be hardened. An energization test was performed on the surface temperature (thermometer 1 to thermometer 5) of the PTC planar heating element taken out from the mold. Table 2 shows the results of the energization test.

  The composition prepared by the above method [0026] and two electrode wires are filled into a cylindrical stainless steel pipe having a diameter of 20 mm × 600 mm, and this pipe is put into an electric furnace, and the temperature is about 70 ° C. for about 20 hours. An energization test was performed on the temperature of a pipe in which a PTC sheet heating element manufactured by forced drying was installed. A copper wire having a diameter of 2.5 mm was used as the electrode wire. Table 3 shows the results of the energization test.

  The composition prepared by the above method [0026] and two electrode wires are filled into a cylindrical stainless steel pipe having a diameter of 20 mm × 600 mm, and this pipe is put into an electric furnace, and the temperature is about 70 ° C. for about 20 hours. The PTC sheet heating element produced by forced drying was inserted into a 40 mm diameter cylinder containing 2 liters of water, and an energization test was conducted on the pipe temperature and water temperature. A copper wire having a diameter of 2.5 mm was used as the electrode wire. Table 4 shows the results of the energization test.

  A prism-shaped sample (10 mm × 12 mm × 100 mm) produced by forced drying for about 12 hours in an electric furnace at a temperature of about 70 ° C. with the composition produced by the above-described method [0026] was prepared, and bending strength was Measured for thickness. The test method was based on JIS standard 7721, using a machine from Shimadzu Corporation (model AG-2000D). As a result, the following results were obtained. Test date: July 1, 2009. Test place: Nagasaki Prefectural Ceramic Technology Center (Ceramics Technology No. 21-66-2).

Sample name-1 = 1.64 MPa
Sample name-2 = 1.35 MPa
Sample name-3 = 1.55 MPa
Sample name-4 = 1.29 MPa
Sample name-5 = 1.13 MPa
(Average) = 1.39 MPa

  A short cylindrical sample (diameter 20 mm × 10 mm) produced by forced drying for about 12 hours in an electric furnace at a temperature of about 70 ° C. with the composition produced by the above method [0026] was prepared, and far infrared rays were produced. The emissivity was measured. The test method used the far infrared spectroscopy radiometer (JIR-E500) by JEOL Co., Ltd., and measured it at the heater temperature of 60 degreeC. For the measurement, only one side of the sample brought in by the applicant was polished and smoothed. The unpolished surface was used as the measurement surface. The integral emissivity was calculated in the wavelength range of 3.33 to 25.42 μm. As a result, the following results were obtained. Test date: June 3, 2009. Test place: Nagasaki Prefectural Ceramic Technology Center (Ceramic Technology No. 21-66-3).

Surface temperature = 48.8 ° C Integrated emissivity = 88.4%

  Glass wool: 1 kg, water: 1 liter, and polyamide-based resin protective material 18 kg (polyamide contains 2.7 kg (= 18 kg × 15%)) are stirred in a stirrer, and thereafter graphite having an average particle size of 8.32 μm: 10 kg of the remaining water: 9 liters was added to the stirrer and stirred for about 30 minutes. The graphite shown in Table 1 was used. Moreover, the polyamide-type resin protective material used what has the component ratio shown to said (0019).

  After the stirring, the molding composition of the PTC planar heating element is poured into a mold having a size of, for example, 250 mm × 300 mm × 12 mm, and two electrode wires constituting a plus electrode and a minus electrode are inserted and the molding composition It was made to project outside from the end of the object to be a current-carrying terminal, and the rest was poured. A copper wire having a diameter of 2.5 mm was used as the electrode wire.

  Thereafter, this was put in an electric furnace and forcedly dried at a temperature of about 70 degrees for about 12 hours to be hardened. An energization test was performed on the surface temperature of the PTC planar heating element taken out from the mold (thermometer 1: the measurement location was set to one location because there was almost no temperature difference). Table 5 shows the results of the energization test.

  A prism-shaped sample (10 mm × 12 mm × 100 mm) made by forced drying for about 12 hours at a temperature of about 70 ° C. in the electric furnace with the composition prepared by the above method [0039] was prepared, and bending strength was Measured for thickness. The test method was based on JIS standard 7721, using a machine from Shimadzu Corporation (model AG-2000D). As a result, the following results were obtained. Test date: April 8, 2010. Testing place: Nagasaki Ceramic Technology Center.

Sample name-1 = 1.9 MPa
Sample name-2 = 1.2 MPa
Sample name-3 = 1.8 MPa
Sample name-4 = 1.6 MPa
Sample name-5 = 1.4 MPa
Sample name−6 = 1.7 MPa
Sample name-7 = 1.6 MPa
Sample name-8 = 1.6 MPa
Sample name−9 = 1.6 MPa
Sample name-10 = 1.5 MPa
(Average) = 1.6 MPa

  A short cylindrical sample (diameter 20 mm × 10 mm) produced by the forced drying in the electric furnace at a temperature of about 70 ° C. for about 12 hours with the composition produced by the above method [0039] was produced. The emissivity was measured. The test method used the far infrared spectroradiometer (JIR-E500) by JEOL Co., Ltd., and measured it at the heater temperature of 100 degreeC. For the measurement, only one side of the sample brought in by the applicant was polished and smoothed. The unpolished surface was used as the measurement surface. The integral emissivity was calculated in the wavelength range of 3.33 to 25.42 μm. As a result, the following results were obtained. Test date: April 8, 2010. Testing place: Nagasaki Ceramic Technology Center.

Surface temperature = 87.9 ° C. Integrated emissivity = 77.9%

DESCRIPTION OF SYMBOLS 1 PTC planar heating element 2 Terminal part for electricity supply 3 Electrode wire 4 Outer frame container 41 Insertion hole

Claims (9)

A PTC planar heating element molding composition comprising graphite, glass wool or / and rock wool, and water as main components. It contains graphite, glass wool or / and rock wool, and water as the main components, and the blending composition is in a weight ratio of 5% to 25% of glass wool or / and rock wool with respect to the ratio of graphite of 1. A composition for molding a PTC planar heating element, characterized by comprising 50% to 100%. A composition for molding a PTC sheet heating element, comprising graphite, glass wool or / and rock wool, water, and a polyamide-based resin as main components. It contains graphite, glass wool or / and rock wool, water, and polyamide-based resin as the main components, and the blending composition is 5% by weight of glass wool and / or rock wool with respect to a ratio of 1 for graphite. A composition for molding a PTC planar heating element, comprising: 25%, 50% to 100% water, and 5 to 40% polyamide resin. 5. The PTC sheet heating element molding composition according to claim 1, wherein the graphite has an average particle diameter of 1 μm to 30 μm. The composition for molding a PTC sheet heating element according to any one of claims 1 to 4, wherein the glass wool is waste. The composition for molding a PTC sheet heating element according to any one of claims 1 to 4, wherein waste is used for rock wool. A part of the composition for molding a PCT sheet heating element according to any one of claims 1 to 7 in an outer frame container in which a side peripheral surface and a bottom surface are surrounded and an upper surface is opened. A method for producing a PTC planar heating element, characterized by pouring the electrode wire on the top and then pouring the remainder, and then drying it. A PTC sheet heating element manufactured by the manufacturing method according to claim 8 and comprising a current-carrying terminal portion connected to an electrode wire.

Images