KR101813685B1 - Manufacturing Method of Sheet Type Heating Element - Google Patents

Abstract

The present invention relates to a method to manufacture a sheet type heating element. According to the present invention, the sheet type heating element is manufactured in a method to combine a heating sheet, which is formed into paper from carbon fiber and pulp, with an insulating material, such as epoxy, thermoplastic polyurethane (TPU), polyethylene (PE), polyethylene terephthalate (PET), etc., and the method comprises a) a heating sheet cutting step, b) a copper tape attaching step, c) an insulating material stacking step, d) a punching step, e) a pressing and stacking step, f) a laminating step, and g) a post-treatment step. Accordingly, a high quality sheet type heating element is manufactured through such processes.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a surface heating element,

BACKGROUND OF THE INVENTION 1. Field of the Invention [0002] The present invention relates to a method of manufacturing a surface heating element based on carbon fiber paper, in which a plurality of perforation holes are formed in a portion of a copper tape adhered to the carbon fiber paper .

The types of heating according to the insulator can be classified into oil and gas heaters, hot air heaters, and electric heaters, and the electric heaters can be composed of near infrared heaters, radiators, and far infrared heaters.

Oil and gas heaters have a problem of harmful gas, noise, surge of oil and fire, and hot-air heaters have difficulty in ventilation, installation difficulty and low thermal efficiency depending on the convection type. In the electric heater, the near- There is a problem of energy loss due to shape limitation and near infrared ray wavelength, and the radiator has a problem in replacement of heat medium, installation and handling.

Conventionally, a conductive carbon paste is used as a heat source. Since such a conductive carbon paste is manufactured by mixing various binders and conductive powder in order to impart continuous conductivity to spherical carbon black, a DC heating element is manufactured It is difficult to manufacture a heating element having a low resistance value. The volume resistivity of the carbon paste may be, for example, 500 OMEGA / cm, and the volume resistivity upon printing and impregnation may be 40 OMEGA / cm ≥ 25 mu m. The heating element to which such a conductive carbon face is applied has a short life span due to oxidation and deterioration of the organic binders contained in the paste when the heating is prolonged for over 80 ° C.

Particularly, the conductive carbon paste is formed by, for example, a method of impregnating and coating weave fabrics. In the impregnating method, a poly yarn or a cotton yarn is woven in a grid shape, then impregnated with a carbon ink, The conductive carbon paste is produced in such a manner that the conductive carbon paste is coated with the insulating material and the cost of the cotton cloth which is the base material for fixing the carbon fluid causing heat generation is high and the amount of the adhesive insulation to the upper and lower insulating sheets There is a lot of difficulty in producing a small amount of thick, which leads to an increase in price.

On the other hand, in the coating weaving method, carbon yarn coated with a conductive compound and a carbon ink on the surface of a poly yarn is twisted into thousands of strands, and after the yarns are arranged in a predetermined shape, The conductive carbon paste is coated or adhered to the surface of the conductive carbon paste. As a result, since the heat source is linear, it has the same heat generation characteristics as the conventional heat ray. There is a risk of local overheating and fire hazard due to hot spot in some short circuits because it is twisted from dozens to several strands for resistance control.

As described above, in the field of film heaters in particular, carbon-impregnated irradiation heaters have been leading the market, but the quality of products has not been stabilized.

On the other hand, the patent documents disclosed in the following prior art documents can be referred to as techniques relating to surface heat generation.

Patent Document 001: Patent Application No. 10-2015-0159281 Patent Document 002: Patent Application No. 10-2016-0183585 Patent Document 003: Patent Application No. 10-2013-0093265 Patent Document 004: Patent Application No. 10-2012-0055888 Patent Document 005: Patent Application No. 10-2016-0081464 Patent Document 006: Patent Application No. 10-2014-0044393

The present invention for solving the above-mentioned problems is intended to provide a method of manufacturing an area heating element having a planar structure.

In order to achieve the above-mentioned objects, the present invention provides a method of manufacturing a carbon heating element, comprising the steps of: a) heating a carbon fiber sheet, which is cut by an automated cutter or manually by a predetermined constant size, A copper tape having an electrode function on both ends of one side is adhered by an adhesive containing a silver component; b) a step of adhering the copper tape to the first and second surfaces, 2) an insulating material is laminated by an automated apparatus or by hand, c) an insulating material is laminated, both ends of the carbon islands having the first and second insulating materials laminated are perforated by an automated punching machine, d) 2) Insulating material, copper tape, and carbon fiber paper are thermally fused to each other by a press machine; e) press lamination step, in which first and second insulating coating layers are laminated on the outer surfaces of the first and second insulating materials, F) a step of laminating the workpiece formed through the step f), and a step of finely cutting the workpiece to a predetermined size in accordance with a predetermined target And g) a post-treatment step in which the finished surface heating element product is completed through a drying treatment, wherein the carbon fiber-coated carbon fiber is composed of 5 to 25% by weight of carbon fiber and 75 to 95% by weight of pulp, The thickness of the carbon islands is in the range of 30 to 60 g / m ² , and the both ends of the carbon islands are perforated by the perforations of the copper tape, And the through holes are perforated.

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Wherein the carbon fiber-supported carbon fiber and the heating paper papered with pulp include at least one of epoxy, thermoplastic polyurethane (TPU), polyethylene (PE), and polyethylene terephthalate (PET) And the like.

And is a planar heating element manufactured by the above manufacturing method.
The method of manufacturing an area heating element, which is applied to a cover body of a heater, which is composed of an outer body, an inner tube, an aluminum panel, and a fabric sheet, There is one feature.

As described above, according to the present invention, it is possible to reduce the manufacturing process of a heating element having a planar surface structure by providing a manufacturing method for a planar heating element based on a tin island pad.

In addition, according to the present invention, since the production process of a heating element having a planar phase structure is reduced, it is expected to save time for production of a heating element having a face-up structure and increase the production amount of a heating element. It is expected to gain a dominant position in the market due to its competitiveness.

Further, according to the present invention, the material constituting the elastic fiber paper and the thickness of the basis weight are limited and presented, whereby the uniformity of the heat generation distribution area can be ensured and the heat generation performance can be improved.

In addition, according to the present invention, since the base of the heating element is an elastic fibrous web, it is possible to produce various sizes of the surface heating element and to show the shape thereof, and it can be utilized remarkably in each application field of the industrial field .

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a block diagram showing the steps of a method of manufacturing an area heating element according to the present invention in a block-
FIG. 2 is a perspective view showing the appearance of the planar heating element manufactured through the drawing shown in FIG. 1,
FIG. 3 is a perspective view showing a laminated structure of the planar heating elements shown in FIG. 2,
FIG. 4 is an exploded view of a planar heating element cut along the perforation hole formed in the planar heating element shown in FIG. 2,
5 is an enlarged photograph of a microscopic image of the elastic fiber paper constituted by the planar heating element according to the present invention,
6 is a conceptual diagram showing an example in which the planar heating element according to the present invention is applied to a cover body of a heater.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed. And it should be interpreted based on the technical ideas throughout the specification taking into consideration that various modifications are made.

In addition, the present invention should not be construed as being limited to the embodiments described below, but should be construed as being broadly construed as including a range of scope that can be extended to various embodiments based on the technical content described in the specification.

The method of manufacturing an area heating element according to the present invention can be applied not only to a conventional carbon paste printing method but also to a method in which carbon fiber and heating paper papered with pulp are coated with an epoxy or a thermoplastic polyurethane (TPU) And is a thin film type far-infrared heat generating body which is manufactured by a combination with an insulating material such as polyethylene (PE) and polyethylene terephthalate (PET)

Hereinafter, the present invention will be described in detail with reference to the accompanying drawings.

The method of manufacturing a planar heating element according to the present invention is characterized in that it comprises the steps of: a) heating a heating paper cutting step, b) copper tape adhering step, c) insulating material laminating step, d) punching step, e) F) laminating, and g) post-processing.

The a) heating sheet cutting step refers to a process of cutting the carbon fiber paper, which is a material of the carbon heating element, to a predetermined uniform size. Cutting can be done with an automated cutter, but manual work is possible in some cases. Here, the carbon fiber cloth is a mixed paper composed of carbon fiber and pulp, and the weight percentage range of the carbon fiber and the pulp is disclosed in the description of the surface heating element to be described later. The above-mentioned mixed paper may also be described as mixed paper, and may be interpreted in the same meaning.

The step b) attaching the copper tape means a process of attaching a copper tape having an electrode function to one end of one side of the carbon islands cut to a predetermined constant size through step a). Since an adhesive containing a silver component is used at the time of attaching the copper tape, the carbon fiber and the copper tape of the adhesive and the carbon islands can be evenly mixed with each other.

The use of an adhesive containing a silver component not only improves the adhesion of the copper tape and improves the conductivity of the copper tape adhering portion but also prevents the unburned phenomenon caused by the copper tape portion It is also aimed at. Of course, such a non-burning phenomenon can be prevented by a punching step which will be described later, although the use of an adhesive containing a silver component is also possible.

The unburned phenomenon (soot due to the occurrence of unburned combustion) can be caused by the conduction failure due to the inflow of impurities (fine dust particles) due to the weakening of the adhesive force at the copper tape portion. Especially, the impurities (fine dust particles) It can be a causative factor, but it can also act as a continuous trigger factor.

The step c) of laminating the insulating material means a step of laminating the first and second insulating materials on one surface and the other surface of the carbonaceous sheet to which the copper tape is attached through the step b). The first and second insulating materials may be resin-based materials such as epoxy and thermoplastic polyurethane (TPU), polyethylene (PE), and polyethylene terephthalate (PET).

The d) punching step is a step of punching both ends of the carbon islands having the insulating material laminated through the step c) using an automated punching machine. Of course, a manual drilling operation may also be performed in some cases.

Here, the punching at both ends of the carbon islands main feature has a main characteristic in puncturing the portion where the copper tape is attached, and means that the copper tape is retained as well as the copper tape and the insulating material are included.

That is, the perforation is made by drilling the insulating material, the copper tape, and the carbon fiber paper all with respect to the portion where the copper tape can be punctured. At this time, the insulating material is cut through the perforation hole H by the perforation process, It is possible to prevent unburned (e.g., soot) phenomenon in the vicinity of the copper tape because it is smudged in the island keeping direction and is filled in a form filled up (boundary is ambiguous).

Here, the unburned (e.g., soot) phenomenon of the periphery of the copper tape is prevented because the boundaries of the insulating material, the copper tape, and the carbon islands due to the punching operation as described above are ambiguous as shown in Fig. 4, (Fine dust particles) due to the strengthening of the adhesive strength of the region or the air is prevented from flowing. In particular, impurities (fine dust particles) or air can be a cause of combustion, but can also act as a continuous triggering factor.

Moreover, the strengthening of the adhesive strength of the copper tape portion here means that there is no invisible micro gap which can be interpreted in the same sense as the improvement of the tightness of the adhesive force, that is, . The absence of micro-gaps is an improvement in conductivity.

The e) press lamination step refers to a process of thermally fusing an insulating material, a copper tape, and a carbon fiber paper to each other using a press machine. Here, the insulating material, the copper tape, and the carbon fiber cloth are adhered to each other, in particular, the adhesion of the puncture site performed in the step d) can be further strengthened.

F) laminating is performed by laminating first and second insulating coating layers on the outer surfaces of the insulating materials (first and second insulating materials), and then coating the first and second insulating coating layers laminated on the outer surface of the insulating material with a laminator .

Here, according to the coating process of the first and second insulating coating layers, a workpiece to be machined is formed by the surface heating element described later.

The g) post-processing step is a step of finally inspecting the workpiece formed through the step f), finishing the precise cutting to a predetermined size, and drying the finished product to complete the final surface heating element product it means.

As shown in FIGS. 2 and 3, the planar heating element 100 manufactured by the manufacturing method described above includes a carbon heating element 10 made of a carbon islands holding material, a carbon heating element 10 made of a material bonded to one surface of the carbon heating element 10 The first and second insulating coating layers 30 and 31 bonded to the outer surfaces of the first and second insulating materials 20 and 21 and the first and second insulating materials 20 and 21, A copper tape 15 adhered to one end of one side of the carbon heating element 10 and a terminal 15a formed at one side of the copper tape 15 between the copper heating element 10 and the copper heating element 10.

The carbon fiber paper may be composed of 5 to 25% by weight of carbon fiber and 75 to 95% by weight of pulp. The weight percentage of carbon fibers may be a product of high-temperature and high- have. That is, the above-mentioned weight percentage range is optimum in the amount required for the fixed arrangement of carbon fibers in the pulp, which is a base material in which carbon fibers are fixedly arranged. If the carbon fiber content exceeds the above range, the amount of carbon fiber is large, but the required amount to be fixedly arranged on the pulp is inevitably limited. If the carbon fiber content is less than the above range, the carbon fiber amount is small, The heat generating function of the heating element is deteriorated.

Here, it is preferable that the carbon fiber paper has a basis weight in a range of 30 to 60 g / m ² , which can reduce the basis weight and improve the electrode printing and electric conduction.

As described above, the surface heating element manufactured by the manufacturing method of the present invention is referred to as an experimental specimen, and the comparison with the experimental specimen is referred to as a control specimen.

The experimental conditions of the test specimens and the control specimens were the same as those of the other specimens except that the weight percentages of the carbon fibers and pulp constituting the carbon fiber paper were different and the basis weight was different.

The test specimens were set to weight percent (basis weight) of 45 g / m ² with the weight percentages of carbon fiber and pulp set at 15% and 85%, respectively, while the control specimen 1 had a weight percentage ratio of carbon fiber to pulp of 4% establish a 96% jeonghamyeo a basis weight (坪量) to 61g / m ^2, control sample 2, establish the% proportion by weight of carbon fibers and pulp by 26% and 74% was defined a basis weight (坪量) to 29g / m ² .

Experimental specimen Control specimen Uniformity Temperature deviation below 5 ℃ Temperature deviation within 10 ℃ Heating temperature Can heat up over 200 ℃ Can heat up below 100 ℃ durability The upper (upper) Medium Thermal spray acidity

As shown in Table 1, the test specimens are superior to the control specimens in that the uniformity of the test specimens is superior to that of the control specimens, considering that the temperature deviation is 5 ° C or less in terms of uniformity compared with the control specimens.

In addition, it can be seen that the test specimen has superior heat temperature performance compared with the control specimen, considering that the test specimen can generate heat of 200 ° C or more in terms of heat temperature compared with the control specimen.

In addition, the experimental specimen is superior to the control specimen in terms of durability. Considering that the specimen is thin in thickness and has a lot of pores, the insulator (for example, epoxy) It is possible to use semi-permanently because the upper and lower parts of the carbon islands are completely filled with the insulating material. However, since the surface heating element of the control specimen has a small size and a small gap, the permeability of the insulating material may be weakened, Permanent lifetime is short due to the occurrence of peeling due to heat.

In addition, the experimental specimens are more uniformly dispersed in the total area of the surface heating element than the control specimen in terms of dispersibility, and thus the deterioration and dispersion of the test specimens are superior to the control specimens .

Based on the results shown in Table 1, the test specimens were superior to the control specimens in terms of uniformity, heat generation temperature, durability, and dispersibility, and the uniformity, heat generation temperature, durability, Dispersibility of carbon fibers is important, and the dispersibility of such carbon fibers is attributed to the basis weight of carbon islands retained and the weight percent reflectance of carbon fibers and pulp constituting the carbon fiber paper.

The insulating materials 20 and 21 may be any one of epoxy resin, urethane resin, and polyethylene (PET) resin depending on the application of the surface heat emission element 100. For example, a frame heater, a personal heater, Epoxies can be used for booths, floor heating materials, industrial heating and drying heaters, and the like. For example, urethane may be used for a heat mats, a heater for house cultivation, a heater for seedling seedlings, a perm cap, a gel warmer, For example, polyethylene may be used for a low-temperature heater or the like.

In the following Table 2, the surface heating element of the present invention is referred to as product A and the other surface heating element as B and C, respectively, and their respective advantages are summarized.

A product
(Carbon fiber surface heating element) B products
(Fiber surface (line-shaped) heating element) C products
(Film shape surface heating element) Main material Carbon fiber, pulp, Carbon paste, cotton yarn Carbon paste, PET Product shape Free size Roll screen, Free size Roll screen Heat characteristic Selected front heat Front heat Carbon print face band shape Heat source Carbon fiber and pulp mixture Cotton weave, Carbon liquid impregnation Carbon liquid film straight type
print Maximum temperature 130 ° C (epoxy) / 80 ° C (for floor heating) 80 ℃ 60 ° C Insulator Epoxy resin, thermal fusion with TPU, PE extrusion Liquid resin or nonwoven fabric, film laminate PET film laminated on both sides Waterproof Excellent moisture resistance and waterproof Waterproofing of border none
Advantages
Reliability, durability and excellent environmental resistance Good flexibility and bending resistance Manufacturing cost minimum cost,
Price cheaper Good temperature distribution Good temperature distribution Large-area heating element configuration
possible Various orders can be produced Easy to adjust resistance value

Disadvantages
High manufacturing cost High manufacturing cost Flexibility, no bending resistance Product size limit
(Epoxy type) Plenty of production units Roll cut insulation operation
difficulty Difficult to adjust resistance value Low heat temperature Difficulty handling power terminal Short life sample picture

As can be seen from the contents of Table 2 above, the A product produced by the present invention is more advantageous than the B and C products in terms of advantages and disadvantages, but has few disadvantages. Considering that the A product is superior to the B and C products .

Conventionally, the heat source of the planar heating element is a carbon paste, but in the present invention, the planar heating element itself is a heat source.

Particularly, in the present invention, carbon fiber as the core material of the heat source can be composed of carbon fiber and pulp. The carbon fiber is a pure PAN-based carbon fiber. The resistance value is determined by the arrangement and content of the net, And serves as a substrate for fixing and arranging carbon fibers.

That is, the carbon fiber is made of carbon fiber and pulp and is made in paper form. As a result, the high-purity carbon fiber itself can be electrically connected with the net, and a low-resistance heating element can be manufactured according to the content and arrangement shape . The volume resistivity of the carbon fiber may be, for example, 1.5 x 10 < ^-3 > OMEGA / cm, and the carbon fiber may be 2.0 to 4,000 ohm / cm. In addition, if it is composed of pure carbon fiber only, it can generate heat at 200 ° C. Since it can be insulated with electrode after cutting in paper form, the surface heating element can be varied in voltage and output from DC to AC. And it is also easy to manufacture.

Such a planar heating element may be composed of, for example, a microfiber structure of 0.06 mm in thickness, such as a microfine carbon fiber, a platelet-like natural pulp and a synthetic special ceramic. Since the planar heating element has a wide heating area, It is possible to secure a heat generating area and realize excellent thermal efficiency and power saving at the same wattage.

In addition, it is possible to provide an excellent lightweight product because the temperature distribution of the heating surface is uniform and the heating element can be designed with a thin thickness of 0.1 mm or less, and the shape and power consumption And the FRP can be molded integrally with the heat generating element and the resin. Therefore, it is possible to provide a variety of designs and convenience, and it is less expensive than carbon-impregnated weaving yarn or carbon coating yarn, It is also possible to realize a heat generation of 100 ° C or more.

On the other hand, since the conventional carbon black paste for heat generation is produced by mixing conductive materials with various binders in order to impart continuous conductivity to spherical carbon black, a heating element having a low resistance value for manufacturing a DC heating element This is difficult. The volume resistivity of the carbon paste may be, for example, 500 OMEGA / cm, and the volume resistivity upon printing and impregnation may be 40 OMEGA / cm ≥ 25 mu m. The heating element to which such a conductive carbon face is applied has a short life span due to oxidation and deterioration of the organic binders contained in the paste when the heating is prolonged for over 80 ° C.

In the impregnation method, a poly yarn or a cotton yarn is woven in a grid shape, then impregnated with a carbon ink, and then dried The conductive carbon paste is processed in such a manner that the conductive carbon paste is processed and then coated with an insulating material. The cost of the cotton cloth, which is the base material for fixing the carbon fluid causing the heat generation, is high and the amount of the adhering insulation to the upper and lower insulating sheets The thicker it leads to the thicker price increase, and the difficulty of small quantity production.

On the other hand, in the coating weaving method, carbon yarn coated with a conductive compound and a carbon ink on the surface of a poly yarn is twisted into thousands of strands, and after the yarns are arranged in a predetermined shape, The conductive carbon paste is coated or adhered to the surface of the conductive carbon paste. As a result, since the heat source is linear, it has the same heat generation characteristics as the conventional heat ray. There is a risk of local overheating and fire due to hot spots in some short circuits because they are twisted to tens of strands to control the resistance.

As the carbon fiber heating core, which is a core material of the planar heating element 100, can be developed and produced in terms of production, it can be expected to have import substitution effect. In terms of quality, it is possible to reduce power consumption compared to existing products, Improvement of strength and durability life by heat fusion, application of eco-friendly material by using carbon fiber instead of conventional hot wire without using adhesive in environmental friendliness, reduction of electromagnetic wave in health and marketing, warmth due to large-area heat generation and far-infrared radiation There is an effect of prevention of quality deterioration due to cost competitiveness due to the localization of the component material of the heating element in terms of competitiveness and reduction of noise due to low power, electromagnetic wave reduction, reduction of fire risk caused by partial closure in terms of safety and safety.

The planar heating element 100 according to the present invention can be applied to various fields and can be applied to a ceiling material, a gypsum board, a wallpaper, a brick, a tile, a panel, a mortar, a paint, In the industrial field, it can be applied to processes such as drying, aging, hardening, molding, firing, heating, preheating, and warming. In the healthcare field, for example, a vulcan sauna, a thermal therapy device, a fuming device, A hair dryer, a stone bed and the like, and in the kitchen appliances field, it can be applied to a cooking device, a griddle, a baker, a teapot, and the like.

The planar heating element 100 of the present invention can be used as a non-heating application in kitchen utensils such as a food storage container (plastic, ceramics, glass), a living porcelain, a front retaining poly bag, a cook, a cooking plate, And can be applied to various products such as socks, undergarments, bed sheets, yogurts, pillows, sheets, fibers and the like in a textile product and various kinds of bands, belts, laces, insole, pads, necklaces, bracelets, And can be applied to automobile articles such as seat covers, handle covers, mats, backrests, and the like.

The planar heating element 100 of the present invention may be configured in such a manner that it is applied to the cover body of the heater 200 as shown in FIG.

That is, the cover body of the warmer 200 is formed in the shape of a hemispherical tunnel, and is composed of an outer body 140, an inner tube 130, an aluminum panel 120, a fabric sheet 110, and an area heating element 100 .

The outer tube main body 140 is formed on the outermost outer layer to protect the inner tube member, the aluminum panel, the fabric sheet, and the surface heating element formed therein, And the aluminum panel 120 is mirror-finished in the inner surface of the inner tube member, and reflects heat energy to be transmitted to the body part through the fabric sheet, The fabric sheet 110 is adhered to the inner surface of the aluminum panel and irradiates far-infrared rays and photocatalysts by reflected heat energy reflected from the aluminum panel. The surface heating element 100 is arranged on the inner surface of the fabric sheet To generate heat energy. Finally, it is used as a heat source for the body treatment effect through antibacterial and sterilizing action on the body part .

Here, since the planar heating element 100 is applied to the cover body of the heater 200, the effect of maximizing the therapeutic effect of the body can be expected due to superior uniformity of the heating temperature, have.

The surface heating element 100 in the present invention can be applied to, for example, an antimicrobial ceramic, a liquid ceramic, a fine ceramic or the like as a raw material for synthesis as a raw material application, and can be applied to alumina silica mineral, magnesia mineral, .

The planar heating element 100 according to the present invention can be manufactured by variously designing the size of the heating surface reference (heater) according to the output density, for example, Table 3 below shows the output density of the carbon- And the surface temperature of the heater according to the data.

Heating temperature (℃)
Output density (W / cm2) Opening Semi open 35 0.032 0.016 40 0.042 0.020 45 0.052 0.025 50 0.061 0.035 55 0.071 0.042 60 0.081 0.051 65 0.092 0.058 70 0.105 0.064 75 0.115 0.071 80 0.130 0.080 85 0.140 0.090 90 0.153 0.099 95 0.163 0.107 100 0.180 0.116 105 - 0.125 110 - 0.142 115 - 0.150 120 - 0.160

* The temperatures in Table 3 may differ depending on the measuring method and the measuring time of the measuring conditions.

The resistance reduction rate is lowered because the contact area between the carbon fibers increases due to the pressure of the laminating (press or extrusion process). Also, the decrease may vary depending on the dry weight of carbon islands (5 ~ 30%).

For example, when the size of the carbon heating element 10 (based on the heating surface of the heater) is 95 cm x 50 cm and the heat generation is 90 ° C, the output of 475 W is required in designing. 475 W is 0.1 W / cm 2 x 95 cm x 50 cm Derived value. Here, the carbon heating element may be interpreted as carbon fiber paper.

For example, the following formula can be used when designing a 475 W output carbon islands manufacturing specification: W (output) = V ² (input voltage) / R (heater resistance) Density, W is the output, R is the resistance, and R ₀ is the volume resistance (Ω / cm 2) of the carbon islands.

W = V ² / R; W = V ² / R; R is (heater resistance) = 220 ^2/475 = 102Ω, where, R ₀ (carbon fibrous volume resistance) × length × resistance reduction ratio R = (resistance of the heater) of the distance / between the copper foil.

That _{is, R 0 (Ω / ㎠)} × 95㎝ / 45㎝ × 0.8 ( resistance reduction) = 102Ω (resistance of the heater as required) according to _{Lim, R 0 (Ω / ㎠)} = 102Ω × 45㎝ / 95㎝ ÷ 0.8 = 60? / Cm 2.

Accordingly, the carbon heating paper 10 having a volume resistivity of 60 ohms and having a size of 95 cm × 50 cm and having a power of 475 W, which is heated at 90 ° C. by the laminating process, can be manufactured.

As described above, according to the method of manufacturing the area heating element according to the present invention, the carbon heating elements can be manufactured in various sizes according to the output density, and convenience of various sizes is also provided.

Surface heating element (100) Carbon heating element (10)
First and second insulating materials (20, 21) First and second insulating coating layers (30, 31)
The copper tape (15) terminal (15a)

Claims (5)

delete A) heat-generating paper cutting step of cutting the carbon fiber paper, which is a material of the carbon heating element, to a predetermined constant size by an automated cutter or manually; (B) a copper tape adhering step in which a copper tape having an electrode function is adhered to both ends of one surface of the carbon islands by an adhesive containing a silver component; C) laminating the insulating material, wherein the first and second insulating materials are laminated on the first and second surfaces, respectively, of the carbon islands with the copper tape attached thereto by an automated device or manually; D) a punching step in which both ends of the carbon islands holding the first and second insulating materials are punched by an automated punching machine; E) press lamination step in which the first and second insulating materials, copper tape, and carbon fiber paper are heat-sealed to each other by a press machine; Wherein the first and second insulating coating layers are coated with a laminator in a state where the first and second insulating coating layers are laminated on the outer surfaces of the first and second insulating materials to form a workpiece to be processed by the surface heating element; ; And g) a post-processing step in which the finished product formed through the step f) is finally inspected, precise cutting is performed to a predetermined target size, and the final surface heating element product is completed through a drying process; Lt; / RTI >
Wherein the carbon fiber is composed of 5 to 25% by weight of carbon fiber and 75 to 95% by weight of pulp, and has a basis weight in a range of 30 to 60 g / m ² ,
Wherein the end portions of the carbon islands are perforated by drilling the portions where the copper tapes are formed and the carbon islands, as well as the copper tape and the first and second insulating materials. 3. The method of claim 2,
It is preferable that at least one of Epoxy, TPU (polyethylene terephthalate), PE (polyethylene) and PET (polyethylene terephthalate) is included in the carbon fiber- Of the surface heat generating element. A method for producing a planar heating element, which is a planar heating element manufactured by the method according to claim 2 or 3. 3. The method of claim 2,
The surface heat emission element completed through the g) post-processing step is applied to a cover body of a heater, which is composed of an outer body, an inner tube, an aluminum panel and a fabric sheet, and is formed on the inner surface of the fabric sheet. ≪ / RTI >

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