KR20070001041A - Manufacturing method of ptc polymer sheet-electrode assembly - Google Patents

Abstract

A manufacturing method of a PTC(Positive Temperature Coefficient) polymer sheet-electrode assembly is provided to perform a crosslink process of PTC polymer composite by applying a microwave energy to the sheet. A manufacturing method of a PTC polymer sheet-electrode assembly includes the steps of: preparing a polymer composite(21) including a polymer resin, a conductive corpuscle filler, and a crosslink agent; forming a sheet(24) by pressing out the polymer composite; applying a crosslink process to the sheet by applying a microwave energy; and forming an electrode on at least one side of the cross-linked sheet.

Description

Manufacturing method of PTC polymer sheet-electrode composite {MANUFACTURING METHOD OF PTC POLYMER SHEET-ELECTRODE ASSEMBLY}

1 is a view showing a polymer thermistor having a PTC characteristic produced by the present invention.

2 is a view showing a crosslinking process performed simultaneously with forming a PTC sheet electrode of the present invention.

3 is a view showing a microwave generating apparatus of the present invention.

4 is a graph showing the PTC characteristics of the polymer thermistor having PTC characteristics for Example 2;

<Description of Main Parts of Drawings>

11: PTC element, 12,27: metal electrode

13: lead wire, 14, 21: PTC polymer composition

15: polymer PTC thermistor, 22: single screw extruder

23: sheet die, 24: PTC polymer composition sheet

25: microwave generator, 26: roll-off

28: laminator heating roll, 29: PTC sheet

31: microwave generating power, 32: circulate

33: dummy load, 34: power monitor

35: impedance regulator, 36: applicator

37: microwave energy

The present invention relates to a method for producing a composite of a PTC polymer sheet-electrode.

In general, the PTC polymer composition is a kind of polymer material used in thermistors that are used as protection elements of electronic circuits. In addition, PTC thermistor is composed of N-type semiconductor type PTC ceramic, which is added with a small amount of rare earth dopant as the main component of BaTiO ₃ , and conductive polymer composition in which conductive filler such as carbon black is added to polymer resin, which is an electrical insulator. PTC polymers using resistance change can be roughly classified. PTC devices made of ceramic materials have been widely used for a long time, but have a relatively high resistance at room temperature, thereby limiting the scope of application and causing high process costs. In order to solve this problem, a conductive polymer composition has been developed that has a small resistance value at room temperature and is easier to manufacture than a ceramic process, and examples thereof include US Patent Nos. 4,237,441, 4,545,926 and 5,880,668. Can be mentioned.

PTC devices are used in various ways such as overcurrent protection of electronic components and circuits, constant temperature heating heaters, TV degaussing, motor starting, temperature sensors, etc. PTC polymers have almost the same functions as existing PTC ceramics, and due to their different reaction temperature, time and volume, they are adopted as protection devices for overload and overheat protection of many electronic parts circuits according to the development direction of light and small parts of electronic parts. It is becoming.

The PTC polymer is basically a conductive material in crystalline polymer resin, so it acts as a conductor (low resistance state) at normal temperature and normal state, but the PTC polymer element itself is caused by excessive heat generated under abnormal conditions such as overload or overheating. As a result of microvolume expansion and amorphous by thermal melting of crystalline polymer, the lattice distance between polymer resin and conductive material dispersed well is rapidly spontaneously transitioned to a non-conductive (high resistance state) range over a certain temperature. At the same time, it has a function to protect the electronic circuit by temporarily blocking the current applied to the electronic circuit.

Factors that govern PTC performance include the types of crystalline polymer resins used, particle size of conductors, specific surface area and electrical properties, and degradation of polymer resins due to mechanical repetitive motion and thermal exposure such as thermal expansion and contraction of PTC devices themselves. The main aspect of PTC polymer device development is to minimize cross-link current and interfacial resistance through securing crosslinks to ensure resin durability enough to overcome the above problems and to secure adhesion between interfaces between electrodes and resin layers.

The mechanism by which PTC phenomena occur in conductive (semi) crystalline polymer compositions filled with carbon black is due to two main factors, the first being the percolation threshold, which begins to form a conductive pathway in the composition. It means critical content. The conductive polymer composition filled with a high content of the filler has a small resistance value at room temperature, but has a very high melt viscosity and breakage of the final product, and also reduces the PTC effect. In other words, the difference in relative resistance values between the room temperature and the high temperature region does not appear so much that the function as a protection device is halved. Second, because of the rapid change in specific volume at the melting point of the polymer due to the change in the volume expansion coefficient at the melting point of the matrix can be expected a relative insulation effect. The room temperature conductivity and the PTC properties of the conductive polymer composition filled with carbon black are affected by various factors such as carbon black structure and content, characteristics of the polymer matrix, mutual attraction between the polymer and carbon black, and processing conditions.

For example, a method of Republic of Korea Patent Application Laid-Open No. 98-703168, the crystallinity is the DBP using 65 ~ 85cm ² / 100g of carbon black as a particulate conductive filler to a high-density polyethylene, and a mixture of them in multiple stages PTC anomaly height increase Is disclosed. Such a method uses a large amount of high-density polyethylene and carbon black as described above, thereby lowering the mechanical properties of the conductive polymer, which results in poor workability and poor adhesion.

In addition, Japanese Patent Laid-Open Publication No. 5-109502 and US Pat. No. 3,351,882 disclose that the surface of the electrode is chemically or physically treated to improve the adhesion between the PTC polymer composition and the electrode, thereby making the surface rough or specially manufactured. An electrode was used. However, these methods not only solve the problem of contact resistance satisfactorily, but also have a drawback in that a few short-circuit currents have a lack of cyclic stability having the same resistance value as the initial stage.

The PTC phenomenon of PTC polymer material is caused by the change of the crystal state and amorphous state in the polymer and the sudden increase of the electrical tunnel formed at the temperature just before the melting point of the polymer resin, resulting in high PTC resistance. However, the use of thermoplastic matrices such as polyethylene results in NTC phenomena due to expansion and rearrangement in which carbon black compressed beyond the PTC transition, ie past the melting point, forms a new conductive network. The NTC phenomenon is presumed to be due to the decrease of the elastic modulus of the polymer at high temperature. The crosslinking process is used to solve this problem, and the crosslinking method is a chemical crosslinking through direct application of thermal energy. A method and a gamma ray or electron beam irradiation crosslinking method using Kinetic Energy of particles are commonly used (US Pat. No. 42,374,41). The conventional chemical crosslinking method has the advantage of obtaining a uniform and efficient crosslinking structure, while crosslinking can proceed during the mixing process of the conductive polymer and the crosslinking aid, resulting in limitations in the mixing process temperature and the press crosslinking process. There is a problem that it is difficult to secure uniformity of quality. The gamma ray or electron beam irradiation crosslinking method is generally performed after the molding is cooled, and after crosslinking in the absence of the flow of molecules, the kinetic energy of the particles is converted into some thermal energy, which causes flow again due to melting of the PTC polymer composition. Due to the change in the structure of the polymer and the movement of the carbon black particles used as the conductive filler, the reproducibility of the PTC characteristics and the resistance value is inferior, and the crosslinking treatment equipment is very expensive (Korean Patent Publication No. 98-703169).

Vaporization of active materials and electrolytes in the battery cell when the temperature of the battery cell itself exceeds 75 ° C due to Joule heat generated by the external terminal short-circuit of the Li-ion secondary battery, which is the power source of the portable electronic device, and abnormal overcurrent caused by overcharging. Due to the increase in pressure and the thermal deformation of the separator, the performance and lifespan of the battery cell itself begin to occur. In particular, when the membrane of the porous structure thin film made of polyolefin having the function of separation of the positive electrode and the negative electrode, short circuit protection, electrolyte protection, and lithium ion permeation is thermally damaged, the pores of the membrane are blocked to limit the movement of the lithium ion. Performance and lifespan are fatally adverse. Therefore, in order to safely maintain the life and performance of the lithium ion secondary battery and to prevent safety accidents, a low trip temperature characteristic is required to effectively block the inflow of overcurrent which causes the temperature rise of the battery cell to the PTC polymer element more quickly. .

As personalization, light weight, and multimedia of portable electronics and information devices are rapidly progressing, power consumption is increased, thereby minimizing power consumption during normal operation of lithium ion secondary batteries requiring high capacity of energy density. In order to realize the extension, a low temperature resistance value characteristic is required for the PTC polymer element.

It is an object of the present invention to provide a method for producing a PTC polymer sheet-electrode composite in which the PTC polymer is crosslinked uniformly and simply.

In the following examples, the case where the PTC polymer sheet-electrode composite is used as the thermistor will be described as an example. However, the PTC polymer sheet-electrode composite according to the present invention is also applicable to a planar heating element. When used as a planar heating element, the electrodes may be formed on both surfaces of the PTC polymer sheet or formed only on one surface thereof. When the electrode is formed on only one surface of the PTC polymer sheet, the double-sided tape may be attached to the other surface of the PTC polymer sheet.

The planar heating element may be applied to a mirror of a car, a car seat, a refrigerator, a kimchi refrigerator, a mat, and a garment.

The method of manufacturing a polymer PTC thermistor (PTC polymer sheet-electrode composite) having low-temperature trip characteristics and low resistance characteristics according to the present invention

(1) PTC polymer composition manufacturing process,

(2) a crosslinking step performed simultaneously with the formation of the PTC sheet electrode,

(3) crosslinked PTC sheet punching process,

(4) soldering process;

(5) It is characterized by including a heat treatment process.

In the above (1) PTC polymer composition manufacturing process, crosslinking aids and antioxidants are dissolved in an organic solvent, one or more powder-type crystalline polymer resins are impregnated in the solution, stirred at a constant speed, and dried in a vacuum oven to obtain an organic solvent. Process for preparing a composition wherein the crosslinking aid is physically adsorbed on the surface of the powder-type crystalline polymer resin, and kneading the conductive particulate filler in at least one polyethylene copolymer with a balbaric mixer or a twin screw kneading extruder above the melting point of the copolymer. To form a composition in which the conductive fine particles are dispersed in the polymer matrix of the polyethylene copolymer, and at least one powder-type crystalline polymer resin composition in which the crosslinking aid and the Adding the dispersed composition It is a process of kneading with a Bambari mixer or a twin-screw kneading extruder above the melting point of the crystalline polymer resin that does not pyrolyze the crosslinking agent to produce a PTC polymer composition,

The crosslinking process simultaneously with the formation of the PTC sheet electrode is performed by extruding the PTC polymer composition with a single screw extruder above the melting point of the crystalline polymer resin in which the crosslinking aid is not pyrolyzed, and through the gear pump and the sheet die. When extruded into sheets, microwaves are irradiated and crosslinked, and a continuous process is a process of laminating metallic foils on both sides of the sheet and then cooling and cutting them to a certain size.

(3) the crosslinked PTC sheet punching process is a step of punching the crosslinked PTC sheet in an appropriate size and shape,

(4) the soldering process is a process for bonding between the metal lead and the metal electrode of the PTC polymer composition,

The heat treatment step (5) is a step for solving the thermal stress of the PTC polymer composition in the manufacturing process of the polymer PTC thermistor.

In the (1) PTC polymer composition manufacturing process, the polyolefin-based crystalline polymer resin is a low density polyethylene (LDPE) having a melt index of 3 to 12, a melting point of 103 ~ 123 ℃, a melt index of 5 to 10, a linear melting point of 110 ~ 130 ℃ At least one selected from the group consisting of low density polyethylene (LLDPE), polyolefin crystalline polymer resin containing a high density polyethylene (HDPE) having a melting index of 1 to 15 and a melting point of 128 to 133 ° C, and a nonpolar polyethylene In order to form a smooth crosslinked structure by microwave energy of the polymer resin and to ensure uniformity of the crosslinking degree of the PTC polymer composition by the uniform distribution of the crosslinking aid physically adsorbed on the surface of the polyethylene polymer resin, More preferred. Polyethylene copolymers include an ethylene acrylic acid (EAA) having a melt index of 3 to 15, a melting point of 60 to 95 ° C, an ethylene methyl acrylate copolymer (EMA) having a melting index of 5 to 15, a melting point of 60 to 90 ° C, and a melt index of 2 to 10. , Ethylene ethyl acrylate copolymer (EEA) with melting point 60 ~ 90 ℃, melt index 2 ~ 15, ethylene butyl acrylate copolymer (EBA) with melting point 80 ~ 100 ℃, melt index 1 ~ 15, melting point 65 ~ 100 ℃ It is preferable to select at least one from the group consisting of polyethylene copolymers containing phosphorus ethylene vinyl acetate (EVA).

In addition, the conductive particulate filler is suitable for nickel powder, gold powder, copper powder, silver plated copper powder, metal alloy powder, carbon black, carbon powder or graphite, particularly, particle size of 50 ~ 90nm, DBP the carbon black levels of 60 ~ 100cm ³ / 100g is preferred.

In addition, as the crosslinking aid, a polar peroxide is used, and 4-chloro tert. butyl perbenzoate, di tert. butyl peroxy terephthalate, 3- tert. It is preferable to select one from the group consisting of polar peroxides containing butyl peroxy-3 (4-chlorphenyl) phthalide.

The composition of the PTC polymer composition is 10 to 50% by weight polyolefin-based crystalline polymer resin, 10 to 50% by weight polyethylene copolymer, 30 to 50% by weight conductive particulate filler, 0.1 to 1% by weight of crosslinking aid, 0.1-0.5 weight% antioxidant is preferable.

The magnetron microwave irradiation method is preferable for the crosslinking process using microwave energy of the PTC polymer composition.

Referring to the present invention with reference to the accompanying drawings in more detail as follows.

2 shows a crosslinking process performed simultaneously with the formation of a PTC sheet electrode according to the present invention.

According to FIG. 2, the PTC polymer composition 21 manufactured through the PTC polymer composition manufacturing process is supplied to a single screw extruder 22 and melt-extruded, and then continuously supplied to the sheet die 23 in a predetermined amount through a gear pump. While performing the crosslinking process by irradiating microwave energy of the applied frequency 2.45 GHz and the maximum output power of 3 kW using the magnetron microwave generator 25 to the extruded thin PTC polymer composition sheet 24, the PTC polymer composition sheet ( 24 is subjected to a process in which the metallic foil 27 released from the roll-off 26 is laminated at a predetermined pressure and temperature between the heating rolls 28 of the laminator and through a cooling tunnel. The PTC sheet 29 is manufactured by being cut to a predetermined size with a cutter while being cooled out.

Microwave energy calorific value P applied to the crosslinking process of a PTC polymer composition is as follows.

P = K f E ² ε tanδ

P: Power Dissipation, W / cm ³

K: Constant, 55.61 ㅧ 10 ^-14

f: Applied Frequency, Hz

E: Electric Field Strength, V / cm

ε: Dielectric Constant

tanδ: Dielectric Loss Tangent

The PTC sheet 29 cut to the predetermined size punches into a suitable size and shape.

A pair of lead wires 13 are respectively bonded to the metal electrodes 12 on both surfaces of the PTC element 11 punched in the appropriate size and shape to form a soldering process.

Through the heat treatment process of the soldered PTC device, the thermal stress of the PTC polymer composition is eliminated in the manufacturing process, and the low temperature trip characteristics and low resistance characteristics of the lithium ion secondary battery can safely maintain the life and performance and maximize the operating time. A polymer PTC thermistor 15 is produced.

The polymer PTC thermistor 15 produced by the present invention is shown in FIG.

Hereinafter, the present invention will be described in detail with reference to Examples. However, the following examples are only examples of the present invention and the present invention is not limited to the following examples.

(Example 1)

a) crosslinking aid di tert. In a solution of 0.9% by weight of butyl peroxy terephthalate and 0.1% by weight of antioxidant in an organic solvent, impregnated with 12% by weight of LDPE (Melt Index) 4 and 6.8% by weight of HDPE (MI 7) for 12 hours after stirring for a certain time. While the organic solvent was removed in a vacuum dryer and the crosslinking aid was physically adsorbed onto the surface of the powder type LDPE / HDPE crystalline polymer resin, and b) 16.1% by weight of EEA (MI 5) and 14.1% by weight of EBA (MI 3). and a particle size of 82㎚, the DBP value is 80cm ³ / 100g of carbon black added to 50% by weight of the night Bari mixer by mixing 115 minutes and once at 110 ℃ 40rpm and preparing the compositions the conductive particle-filled, c) The composition prepared by the steps a) and b) was introduced into the balvarie mixer and kneaded three times for 10 minutes at 140 ° C. and 40 rpm, the temperature at which the crosslinking aid was not pyrolyzed, to prepare a PTC polymer composition, followed by an application frequency of 2.45 GHz, Condition of applied output 1.5kW The polymer PTC thermistor was manufactured by forming an electrode of the PTC sheet at the same time as crosslinking and punching, soldering, and heat treatment.

(Example 2)

a) crosslinking aid di tert. In a solution of 0.9% by weight of butyl peroxy terephthalate and 0.1% by weight of antioxidant in an organic solvent, impregnated with 12% by weight of LDPE (Melt Index) 4 and 6.8% by weight of HDPE (MI 7) for 12 hours after stirring for a certain time. While the organic solvent was removed in the vacuum dryer and the crosslinking aid was physically adsorbed onto the surface of the powder type LDPE / HDPE crystalline polymer resin, and b) 19 wt% EVA of MI 6, 11.2 wt% of EBA of MI 3 and a particle size of 82㎚, the DBP value is 80cm ³ / 100g of carbon black added to 50% by weight of the night Bari mixer by mixing 115 minutes and once at 110 ℃ 40rpm and preparing the compositions the conductive particle-filled, c) The composition prepared by the steps a) and b) was introduced into the balvarie mixer and kneaded three times for 10 minutes at 140 ° C. and 40 rpm, the temperature at which the crosslinking aid was not pyrolyzed, to prepare a PTC polymer composition, followed by an application frequency of 2.45 GHz, Condition of applied output 1.5kW At the same time cross-link the electrodes of the PTC sheet to and through the punch, soldering, and a heat treatment process to prepare a polymer PTC thermistor.

(Comparative Example 1)

Prepared in the same manner as in Example 1, but the crosslinking of the PTC polymer composition was made through electron beam irradiation of 100Mrads of particle energy.

(Comparative Example 2)

Prepared in the same manner as in Example 2, the crosslinking of the PTC polymer composition was made by electron beam irradiation of 100Mrads of particle energy.

The properties of the polymer PTC thermistors prepared according to Examples 1 and 2 and Comparative Examples 1 and 2 are shown in Table 1 below.

                                TABLE 1

Room Temperature Resistance (R ₁ ) ohmcm Resistance after trip (R _1MAX ) ohmcm Trip time (sec.) PTC Strength Log (R ₁ / R _MAX ) Example 1 0.38 0.71 4.5 4.7 Example 2 0.45 0.82 4.2 4.6 Comparative Example 1 0.81 1.56 5.3 3.9 Comparative Example 2 0.89 1.75 4.9 3.7

According to the results of Table 1, the polymer PTC thermistor according to the present invention has a resistance R ₁ of 0.45 ohmcm or less at room temperature (25 ° C.), and a resistance (R _1MAX ) of 0.82 at room temperature (25 ° C.) after tripping. It can be seen that the trip time is within 4.5 seconds and the PTC strength is 4.6 or more when ohmcm or less, 12V / 4.2A power is applied.

According to the present invention as described above, there is provided a method for producing a PTC polymer sheet-electrode composite in which the PTC polymer is crosslinked uniformly and simply.

Claims (8)

In the method of manufacturing a positive temperature coefficient (PTC) polymer sheet-electrode composite, Preparing a polymer composition comprising a polymer resin, a conductive particulate filler, and a crosslinking aid; Extruding the polymer composition to form a sheet; Cross-linking by applying microwave energy to the sheet; Forming an electrode on at least one surface of the cross-linked sheet manufacturing method of the PTC polymer sheet-electrode composite. The method of claim 1, The kneading is, A method of manufacturing a PTC polymer sheet-electrode composite, characterized in that it is carried out at a temperature higher than the melting point of the polymer resin and lower than the thermal decomposition temperature of the crosslinking aid. The method of claim 1, The polymer resin is a method for producing a PTC polymer sheet-electrode composite, characterized in that it comprises a polyolefin-based crystalline resin and a polyethylene copolymer. The method of claim 3, Preparing the polymer composition, Preparing a first polymer composition comprising the polyolefin-based crystalline polymer resin and the crosslinking aid; Providing a second polymer composition comprising the polyethylene copolymer and the conductive particulate filler; A method for producing a PTC polymer sheet-electrode composite, comprising kneading the first polymer composition and the second polymer composition. The method of claim 4, wherein Preparing the first polymer composition, Dissolving the crosslinking aid in an organic solvent; The method of manufacturing a PTC polymer sheet-electrode composite comprising the step of impregnating the polyolefin-based crystalline polymer resin in an organic solvent in which the crosslinking aid is dissolved. The method of claim 4, wherein Preparing the second polymer composition, And kneading the polyethylene copolymer and the conductive particulate filler above the melting point of the polyethylene copolymer. The method of claim 1, The polymer composition is 10 to 50% by weight polyolefinic crystalline polymer resin, 10 to 50% by weight polyethylene copolymer, 30 to 50% by weight of the conductive particulate filler, 0.1 to 1% by weight of the crosslinking aid, 0.1 to Consisting of 0.5% by weight of antioxidant, The polyolefin crystalline polymer resin is at least one selected from the group consisting of low density polyethylene (LDPE), linear low density polyethylene (LLDPE), high density polyethylene (HDPE), The polyethylene copolymer includes ethylene acrylic acid (EAA), ethylene methyl acrylate copolymer (EMA), ethylene ethyl acrylate copolymer (EEA), ethylene butyl acrylate copolymer (EBA), ethylene vinyl acetate (EVA) One or more are chosen from The crosslinking aid is 4-chloro tert.butyl perbenzoate, ditert butyl peroxy terephthalate, 3-tert butyl peroxy-3 (4-chlorophenyl At least one selected from the group containing phthalide (3-tert.butyl peroxy-3 (4-chlorphenyl) phthalide), And the conductive particulate filler is carbon black. The method of claim 1, Wherein the electrode is formed on both sides of the crosslinked sheet.

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