KR100974272B1 - Method for manufacturing the sheet shaped heat element using fabric - Google Patents

Abstract

PURPOSE: A manufacturing method of a planar heating element is provided to improve the adhesive force between an exothermic material and an electrode by using a conductive bonding agent. CONSTITUTION: A conductive bonding agent is spread in one side of an electrode to the thickness of 3um or 5um with a binding agent coating roller(S1). The conductive bonding agent is solidified with a heat duct at the temperature of 140°C to 180°C(S2). The electrode and an exothermic material are welded(S3). An electrode-attached heating material is impregnated in a carbon solution(S4). The electrode-attached heating material is dried(S5).

Description

Method for Manufacturing The Sheet Shaped Heat Element Using Fabric

The present invention relates to a method for producing a planar heating element, and more particularly, to a method for bonding a copper plate to a fabric using a binder containing carbon.

According to Korean Patent Publication No. 10-0668052, a 'carbon fabric planar heating element and its manufacturing method' is disclosed. According to this, the structure which attaches electrode bodies, such as a copper plate, to the surface of the heat generating body formed from the elastic fabric through the carbon binder which is an electrical conductor is disclosed. According to this, it can be seen that even by frequent and severe deformation, it is possible to prevent the occurrence of play between the heating element and the electrode body and to prevent electrical cracks on the heating element, thereby preventing safety accidents such as fire.

However, the above publication does not disclose a specific method for attaching the electrode body to the fabric. Therefore, those skilled in the art could implement the contents of the above registration invention using various types of binders within the scope of their technical common sense, but the effect was unsatisfactory. That is, it was found that the suitability of the product in terms of durability and robustness was not satisfactory. Although many planar heating elements made of synthetic resin films have been supplied in the past, the advantages of the planar heating elements made of carbon-containing fabrics (hereinafter, referred to as `` fabric type planar heating elements '') are known to some people. to be. Woven planar heating elements are superior to synthetic planar heating elements in a use environment in which a large number of folds or wrinkles may occur without a fixed shape such as cushions, mats, clothes or automobile seats.

In the woven planar heating element, it is a very important problem to join the electrode body, which is usually made of copper, to the fabric while maintaining the electrical conductivity. Joining method of the electrode body and the fabric is as follows.

First, there is a method of sewing with a thread after the electrode body back to the fabric. Threads are embedded in the electrode body as dots. That is, the electrode body is coupled to the fabric in the form of point contact.

According to this, the electrode body can be firmly bonded to the fabric at least mechanically. However, there is a problem with the integrity of this method. If frequent folds occur, the parts that are not sewn generate a gap between the fabric and the electrode body, and spark or heat concentration occurs by the gap.

Second, there is a method of weaving copper wire thinner than hair and then weaving several strands of copper wire and fabric directly (see Korean Utility Model Registration No. 20-0375247). In this case, the mechanical and electrical bonding between the electrode body and the fabric is good, and there is no problem in durability in use. However, there is a problem in connecting the terminal and the electrode body in the process of manufacturing the final product.

In order to connect the terminal and the electrode body, first, the slender copper wire of several strands integral with the fabric must be separated from the fabric. This is because the outer terminal and the copper wire of the electrode chain should be connected by soldering at the end of the fabric. For this purpose, a method of extracting copper wire by applying heat to melt the end of the fabric is used. In this case, some strands of the thin copper wire may be lost by melting by the heat. As such, there is a fatal problem that electrical connection between the electrode chain copper wire and the external terminal is very difficult. And in order to meet the heat generation or power consumption required by the consumer, a very complex process, such as weaving fabrics and copper wires from the beginning, must be done in different ways. In other words, it is very difficult to respond to small orders such as samples.

In response to this problem, the present inventors have proposed an abstract method of connecting the fabric and the electrode body by using a conductive binder through the above patent. This is because the contents of the binder and the specific method of the adhesion method are protected by the know-how.

The main object of the present invention for the above problems, in the fabric-like planar heating element, to present in detail a method for physically bonding the fabric and the electrode body through the electricity.

The above object is to bond the electrode body in the form of a metal strip to the surface of the heating material made of fabric and infiltrate the carbon in the heating material in the bonded state, thereby causing the heating material containing carbon to In the method of manufacturing a fabric-like planar heating element to generate heat by receiving electricity through;

Applying a liquid conductive binder to a thickness of 3 to 5 μm on one surface of the electrode body while releasing the electrode body wound in a roll at a speed of 2.5 to 3.5 m / min; Curing the binder applied to the electrode body while passing through a heating duct maintaining a temperature of 140 to 180 ° C .; Compressing and bonding the electrode body passing through the heating duct and the heating material; The component of the binder,

(A) 68 to 72% by weight of the binding material based on polyester, polyurethane and ethyl acetate

(B) 8 ~ 12 wt% of curing agent

(C) 12 ~ 16 wt% of ethyl acetate (EA)

(D) 5 to 7% by weight of powdered carbon (C)

It is achieved by a method for producing a woven planar heating element, characterized in that consisting of.

According to a feature of the present invention, the bonding material may be composed of 60 to 70% by weight of the composite agent of polyester and polyurethane, 30 to 40% by weight of ethyl acetate.

According to another feature of the invention, the curing agent may be composed of 0.1 to 0.5% by weight of aromatic polyisocyanate, 20 to 30% by weight of ethyl acetate (EA) and 70 to 75% by weight of resin.

According to another feature of the invention, the woven fabric is used to weave a cotton yarn of 740 ~ 800 denier 14 to 18 mesh (mesh).

According to another feature of the present invention, after the electrode body is attached, the impregnation and drying of the carbon solution is finished, urethane film, PV film (PVC) film, polyethylene (PE), polycarbonate A laminating process for pressing an insulating film such as (PC) with a heating roller may be added.

According to the above configuration, it is possible to bond the electrode body made of copper plate and the heat generating material made of fabric with good adhesion strength so as to conduct electricity. Since the heating material is a fabric, the surface heating element can be used for various purposes, and since the adhesiveness between the electrode body and the heating material is excellent, there is no partial lifting even if frequent folding or wrinkle occurs, so it is safe to use. In addition, since the thickness, width, and installation intervals of the electrode body can be easily reset, it is possible to easily manufacture and supply a planar heating element suitable for the heating value or power used by the consumer.

1 is a block diagram of the entire manufacturing process of the planar heating element according to an embodiment of the present invention, Figure 2 is a block diagram of the system.
3 is an enlarged view of a main part of FIG. 2.
4 is a photograph of a portion of a heating material according to an embodiment of the present invention.

Hereinafter, with reference to the accompanying drawings in the detailed description of the present invention will be described in more detail. 1 is a block diagram of the entire manufacturing process of the planar heating element according to an embodiment of the present invention, Figure 2 is a block diagram of the system. 3 is an enlarged view of a main part of FIG. 2. 4 is a photograph of a portion of a heating material according to an embodiment of the present invention. Hereinafter, a description will be given with reference to FIGS. 1 to 3. On the other hand, the following description of the entire process has a portion overlapping with that disclosed in the Patent No. 10-0668052 and the overlapping portion will be briefly described.

A thin band-shaped electrode body 1 and a heat generating material 3 wound in a roll form are prepared. The heat generating material 3 is a woven fabric of 740 to 800 denier cotton yarn 14 to 18 mesh is used.

The adhesive container 5 having an open top contains a liquid carbon binder (7, hereinafter simply referred to as a 'binder'). A portion of the binder roller 9 is also impregnated with the binder 7.

As the binder coating roller 9 is in close contact with the electrode body 1, the binder is applied to one surface of the electrode body continuously while being rotated by a force pulling the electrode body 1 from the rear (bonding coating step S1).

After the binder coating step S1, a curing step S2 for semi-curing the binder 7 to the extent that the adhesive force reaches the highest point is followed. The heating duct 11 is used in the curing step S2. The heating duct 11 maintains a temperature of 140 ~ 180 ℃.

After the curing step (S2), the bonding step (S3), the impregnation step (S4, or dyeing step) is sequentially followed.

The bonding step S3 is a step of bonding the two by bonding the electrode body 1 and the heat generating material 3 together. In this process, the semi-hardened binder 7 is soaked between the fine fluffy cotton of the heat generating material (3) to increase the bonding force.

The impregnation step S4 may also be referred to as a dyeing step, and is a fixation in which the carbon solution 12 is impregnated with the heat generating material 3 ′ with the electrode body. Immediately after the impregnation step S4, the drying step S5 takes place. Impregnation step (S4) and drying step (S5) is repeated two or three times. The heat generating material 3 'with the electrode body absorbs carbon while passing through the impregnation step S4. The carbon concentration of the carbon liquid and the number of repetitions of the impregnation step (S4) and the drying step (S5) are important factors for determining the calorific value or power consumption, and can be increased or decreased as necessary. In the drying step S5, a pressing step of squeezing the carbon liquid 12 by the urethane pressing roller 14 having a surface may be added to shorten the drying time.

After the impregnation step (S4) and the drying step (S5), the laminating step (S6) for coating the insulating film 13 on both sides of the heating material (3 ') with the electrode body is performed immediately. As the insulating film 13, a synthetic resin film such as urethane film, PVC film, polyethylene (PE), polycarbonate (PC), or the like may be used. In the laminating step S6, the heating roller 15 adheres the insulating film to the upper and lower surfaces of the heating material 3 'with the electrode body. The cutting process (S7) may be made to cut the edge portion in succession to the laminating process (S6), and after the cutting process (S7), the finished product is wound up and taken out in a roll to finish the production of the heating element.

Laminating step (S6) is also a feature of the present invention. Laminating directly after the discharge of the heating material (3 ') containing the different physical properties, the fabric of the heating material (3) and the copper plate (銅版) of the electrode body 1 (completely after the drying process (S5)). The production of the heating element becomes extremely efficient by carrying out this process.

For reference, the temperature of the working environment is based on 20 ~ 30 ℃.

The main core of the present invention is a binder for bonding the electrode body 1 and the heating material 3 to the bonding method using the same and will be described below.

The conductive binder 7 is preferably set to be applied to one surface of the electrode body 1 to a thickness of 3 to 5 μm. Component of the binder (7) according to an embodiment of the present invention,

(A) 68 to 72% by weight of the binding material based on polyester, polyurethane and ethyl acetate

(B) 8 ~ 12 wt% of curing agent

(C) 12-16 wt% of ethyl acetate (EA) as a solvent

(D) 5 to 7% by weight of powdered carbon as conductive material

It consists of.

Here, the binding material may be composed of 60 to 70% by weight of the composite agent of polyester and polyurethane, 30 to 40% by weight of ethyl acetate (acetic acid ethylether). In addition, the curing agent may be composed of 0.1 to 0.5% by weight of aromatic polyisocyanate, 20 to 30% by weight of ethyl acetate and 70 to 75% by weight of resin.

The binder 7 is blended with each of the above-mentioned materials, and then aged in a temperature of 4 to 10 ° C. for 10 to 14 hours before being put into the adhesive container 5. Carbon is preferably 100% pure.

The strip-shaped electrode body 1 may have various widths and thicknesses according to the specifications required by the planar heating element. For example, the electrode body 1 may have a thickness of 120 μm and a width of 3, 5, 7, 9, or 12 mm. In the state in which the electrode body 1 is pulled taut (a tension of 80 to 90% of the yield strength is applied), the binder 7 is applied and adhered to the heat generating material 3. In application of the binder, it is preferable that the width of the binder roller 9 be wider by 1 mm from side to side than the width of the electrode body 1. This is because the binder 7 is applied too much to the upper surface of the electrode body 1 when the binder roller 9 is wide.

Since the planar heating element manufacturing process of the present invention is a continuous process, the working speed is constant throughout the process, which is 2.5 to 3.5 m / min under the above-mentioned conditions.

4 illustrates a state in which carbon penetrates the heating material while the electrode body is bonded to the heating material. 4 expresses that the electrode body 1 and the heat generating material 3 are bonded together in a crumpled state. The soft heating material 3 is slightly stiffly changed and the electrode body 1 is integrally bonded to the heating material even when there are frequent wrinkles or folding.

One ; Electrode body 3; Heating material
5; Adhesive containers 7; (Carbon) binder
9; Binder coating roller 11; Heating duct
12; Carbon liquid 13; Insulation film
14; Compression roller 15; Heating roller

Claims (5)

By adhering the metal strip-shaped electrode body to the surface of the heating material made of fabric and infiltrating carbon into the heating material in the bonded state, the heating material containing carbon receives electricity through the electrode body In the manufacturing method of the fabric-like planar heating element to generate heat;
Applying a liquid conductive binder to a thickness of 3 to 5 μm on one surface of the electrode body while releasing the electrode body wound in a roll at a speed of 2.5 to 3.5 m / min; Semi-curing the binder applied to the electrode body while passing through a heating duct maintaining a temperature of 140 to 180 ° C; Compressing and bonding the electrode body passing through the heating duct and the heating material; The binder,
(A) 68 to 72% by weight of the combined raw material consisting of 60 to 70% by weight of the composite agent of polyester and polyurethane, 30 to 40% by weight of ethyl acetate
(B) 8 to 12% by weight of a curing agent consisting of 0.1 to 0.5% by weight of aromatic polyisocyanate, 20 to 30% by weight of ethyl acetate and 70 to 75% by weight of resin.
(C) 12 to 16% by weight of ethylene acetate (EA)
(D) 5 to 7% by weight of powdered carbon (C)
It is to be aged for 10 to 14 hours at a temperature of 4 to 10 ℃ blended with;
The binder is applied by contacting the electrode body while rotating the binder roller partially impregnated in the adhesive container;
The heating material is a manufacturing method of a woven planar heating element, characterized in that the woven yarn of 14 ~ 18 mesh (740) of denier (740 ~ 800 denier).
delete delete delete The laminating process of claim 1, wherein an insulating film such as urethane film, PVC film, polyethylene (PE), polycarbonate (PC), or the like is pressed on both surfaces of the heating material to which the electrode body is attached. Method for producing a woven planar heating element, characterized in that the addition.

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