KR20070079770A - Method of manufacturing net heating element - Google Patents

Abstract

A method for fabricating a PTC(Positive resistance/Temperature Coefficient) resistor gauze heating element is provided to reduce the danger of fire due to over-load by making PTC resistor impregnant solution using resistance-temperature(R-T) characteristics, voltage-current(V-I) characteristics and current-time(I-T) characteristics. In a gauze heating element heated by electric characteristics, one iron wire is made by winding several lines of conductive iron wires made of gold, silver, copper, stainless steel, nichrome and nickel, in order to reinforce a polar line. Fabric is made by weaving an assembled line together with flexible fibers by assembling the iron wire.

Description

Method for manufacturing constant temperature resistance (PTC) mesh heating element, power part and durability reinforcement {omitted}

1 is a photograph of the conductive iron wire before the twisting.

Figure 2 is an enlarged photograph of the flexible fiber yarn twisted to increase absorption

Figure 3 is an example of weaving wire and flexible fiber yarn for power supply reinforcement

4 is a photograph showing two, three, four, multiple forms of polar lines for selective heating

5 is a mixed photograph of a flexible fiber yarn and a rigid synthetic resin for adjusting power usage.

6 is a photo of a large and small size of the structure for adjusting the power consumption

7 is a temperature characteristic of the mesh heating element according to the moving point of

8 is an impregnation, drying process diagram of the mesh heating element

Figure 9 is a picture of the finished product according to the impregnation, drying of the mesh heating element

10 is an insulating coating process using a polyethylene film

Figure 11 is a product picture of the finished product with pet molding insulation coating

12 is a product picture of the finished product coated with urethane molding

13 is a urethane forced crimp insulation process diagram

Figure 14 shows the folded portion of the polar line

Figure 15 is a product photograph of the finished product urethane forced compression insulation

Fig. 16 is a flow chart of panel type insulation molding lamination.

Figure 17 is a product picture of the panel-shaped insulation molded finished product

Explanation of symbols on the main parts of the drawings

11: exploded picture of the twisted wire 12: enlarged picture of the twisted wire

21: twisted flexible fiber yarn

41a: + pole, 41b: -pole 42a: + pole, 42b: -pole

43: four poles example 44: multiple poles example

51: Mixed Example of Flexible Fiber Yarn 52: Mixed Example of Rigid Synthetic Resin

61: Example of increased use resistance by increasing the size

62: Example of lowering the use resistance by reducing the size

81: impregnated mesh fabric before coating 82: process impregnated in a carbon liquid container

83: process to squeeze and squeeze 84: process to punch holes blocked in 83 process

85: drying process in the drying bin

86: Toprotor rotation process to loosen the fabric

87: Blowing pipe installed to recycle hot heat from heat blower to increase drying efficiency

88: process of ironing impregnated fabric from drying bin

89: crimping process to prevent deformation of resistance

81a: Net heating element with impregnation and drying process

91:89 finished net heating element, 92: 81a finished heating unit

93: 81a partial incision, 94: 81a rolled mesh heating element

95, 96: partial enlargement of impregnated polar lines and mesh

10a, 13a,: heating element before coating,

10b: Resin film that is aged by applying acrylic adhesive

10c, 10e: process of pouring liquid resin

10d: Press process to prevent air from entering into the compression roller

11a, 11b: pet insulation molding coated product,

11c: Enlarged pole part of the product coated with pet insulation molding

13b: urethane film 13c: process of applying heat to the film with a hot air blower

13d: Pressing process with pressing heat roller 13e: Forced pressing coated product

14a: Folded pole part 14b: Polar part loosened naturally

16a: Adhesive having insulation and hardening component 16b: Glass fiber

16c: mesh heating element

Conventional technology uses a heating wire (nichrome wire), which is usually made of metal, in a heating device to generate heat by electrical resistance, or forms conductive carbon in a yarn to make a heating plate in the form of a mesh, or screen-prints a conductive paste on the film. Heating plate was used

However, these products always pose a risk of fire due to overheating, and since the nichrome heating wire has extremely low thermal efficiency, and the form of carbon yarn is mainly made of carbon, it is required to produce a low resistance product. It is difficult to make a uniform temperature distribution over the whole because it is accompanied by high temperature in the hot wire itself and it is difficult to meet a constant resistance. When using the electrode part as one polar line, problems such as breakage of the electrode wire during processing It is possible to make a heating plate by screen printing conductive paste on the film, which is extremely fragile in electrode bonding, so it is a risk of fire at all times in flexible places, and when the time passes by laminating bonding, the bonding is separated by aging and sparks due to disconnection There is a risk including the phenomenon and is considerable in the handling This was a difficult problem in many ways, to be yo.

Accordingly, the present invention has been invented to solve the above problems, BaTiO3 is a kind of N-type oxide semiconductor that is made conductive by adding a small amount of rare earth element to BaTiO3 in the production of constant temperature resistance (PTC) mesh heating element The crystal structure of is tetragonal below the Curie temperature, but changes to cubic above the Cuie temperature, so the resistance value rapidly increases above the Gyuri temperature, and a part of Ba is replaced by Sr or Pb. Curie temperature can be shifted and "The device has the property of rapidly increasing the resistance value as the temperature rises by phase transition when certain temperature is reached. Resistance-temperature characteristic (RT), voltage-current characteristic (IV ), Using the three characteristics of the current time characteristic (IT) to create a constant temperature resistance impregnation solution to reduce the risk of fire due to overheating prevention, and the development of impregnation process It is to be given a temperature distribution, and at the same time He significantly reduced the risk of the power supply disconnection the power supply to the development of the production and coating method of the fabric reinforcement greatly enhance the durability and allows for selective heat generation portion by the user.

The present invention for achieving the above object,

In the mesh heating element that is generated by electrical characteristics, the reinforcement of the polar wires for the fabrication of the power source and the fabric for durability reinforcement is made of conductive materials such as gold, silver, copper, stainless steel, stainless steel, nickel, nickel, and the like. Twist the wire (11) to make a single wire (12), as shown in Figure 2 in order to increase the absorbing power of the mixed liquid twisted several strands of cotton, cotton blended yarn to make one flexible fiber (21), as shown in Figure 3 By gathering together, the assembly line is continuously made on both sides to form a woven fabric together with a flexible fiber yarn in the form of a net such as longitudinal, transverse, and diagonal lines. As shown in FIG. 42a, 42b), four rows 43, and depending on the application, a number of polar lines 44 can be used and are a useful way of enabling selective partial heating by the user. ) Is shown in FIG. This cotton, cotton blend spinning and other materials that can absorb the mixed solution is sufficient, these can be used mixed with each other, the mixed solution, such as nylon yarn, PP, glass fiber yarn is not absorbed, the heat-resistant rigid synthetic resin yarn 52 weft or When used in combination with warp, weft and warp, it functions to adjust the watt (W), which is the power used per unit area, while maintaining the heating temperature of the impregnated fabric itself. The structure is ideal, but not limited thereto, and is not limited to various shapes such as hexagons, triangles, and polygons, and each structure has a large size as shown in FIG. 6 (61) to increase the resistance or decrease the size (62) to reduce the resistance. Perform each function. Conventional planar heating element and linear heating element products have a lot of carbon coating on the car body, and the wattage is adjusted by reducing the wattage. It is.

In the net heating element generated by electrical properties, barium titanate (BaTiO3) and carbon material, PVA, EVA, binder, penetrant dispersant, and antifoaming agent are used to prepare a mixed solution for constant temperature resistance, wherein barium titanate is contained in a small amount of BaTiO3. A type of N-type oxide semiconductor that has conductivity by adding a rare earth element, and the crystal structure of BaTiO3 is tetragonal below the Curie temperature but changes to a cubic system above the Curie temperature. After mixing the water using the ball mill to prepare a liquid mixture to be dispersed sufficiently. Important here is the selection and blending ratio of the stock solution required for the preparation of the mixed liquor, and the stock selection and blending ratio are important technologies.

The blending ratio is 0 to 80 parts by weight of barium titanate (BaTiO3) having a silica temperature of 70 ° C. and 0 to 80 parts by weight of carbon material, 5 to 40 parts by weight of PVA, 5 to 80 parts by weight of EVA, and 5 to 80 parts by weight of binder. , 5 to 20 parts by weight of penetrant, 2 to 20 parts by weight of dispersant, 2 to 20 parts by weight of antifoaming agent, and 300 to 1000 parts by weight of water are mixed to determine the ratio.

The function of each material is to heat the barium titanate (BaTiO3) and carbon material, and the PVA, EVA, and binder are strongly attached to the fabric to prevent the oxidation of barium titanate (BaTiO3) and carbon material to the power supply and durability. The penetrant is used to infiltrate the mixed solution well into the yarn, the dispersant serves to prevent the mixed solution from agglomerating, and the antifoaming agent is used to prevent foaming during solution ball milling.

It is to be understood that the compounding ratio and type and number of strands described above are not fixed, but may be used by appropriately increasing or decreasing them according to each use depending on the magnitude of power supply voltage, power consumption, and calorific value.

7 is a mesh heating element temperature characteristic due to moving the moving point

In the net heating element generated by electrical characteristics, the technique of impregnation and drying process for even temperature distribution is based on the process 82 of impregnating the mesh fabric 81 in the mixed solution as shown in FIG. The squeezing and compacting process (83) is a process to have an even temperature distribution, and the blowing process (84) that blows a strong wind to remove the blockage of the mixed solution by the squeezing and compacting process is an important technique. There was no process to squeeze and squeeze with the compacting roller, so the mixture did not penetrate into the yarn, so it could not have an even temperature distribution. The number of pressing rollers is not limited in the pressing process. If the drying process is performed with the hole blocked in the mesh, the resistance of the blocked portion is lowered, causing problems because the insulation part is broken or the temperature is not evenly distributed when the power is applied. In addition, the drying process is the first drying in the drying barrel 85 through the rotary annealing process (86) so that the fabric evenly dissipated in the grooved top roller, the second drying using the thermal roller (88) to prevent deformation of the resistance during coating In order to produce a thermostatic resistance (PTC) mesh heating element 81a fabric of an even temperature distribution by pressing the thermocompression roller (89). In order to recover the waste heat and improve the heat efficiency of drying, the drying tank is installed with a heat recovery blower tube 87 to be used continuously. Here, the drying process in the drying container is not limited to the above process, but there is also a method using a commercially available tenter. . Through the above process to obtain the result as shown in FIG.

In the net heating element generated by electrical characteristics, the insulation coating process for strengthening the durability of impregnated fabric has a lot of effect on the durability according to the insulation coating method, and the existing coating method was used by laminating PET film. There were many problems in disconnection and fire.

In the net heating element generated by electrical properties, the PET molding coating method is applied to the PET film by applying an acrylic adhesive to the maturing process (10b) and then impregnated with a liquid PE (10e, 10c) melted at a high temperature as shown in FIG. After the first molding compression (10d) work with the fabric (10a) once again by applying the acrylic adhesive to the PET film in the same process again in the same process, the film is molded and crimped on both sides of the film fabric first coated with liquid PE As a coating process, there is a safe PET molding insulation coating method without disconnection even when folded or bent as shown in FIG. 10. Here, liquid PE can use LDPE to give more flexibility, and the PET film of the first crimping process is the film of the second crimping process. 10 ~ 50% thicker than 10 ~ 50% more PE liquid or before molding together with fabric, insulation film is additionally molded and bonded with fabric and then compressed into primary compression hole Even if the fabric is stuck in the film on time, leakage of current can be prevented and the result shown in FIG. 11 is obtained through the above process.

In the net heating element heated by electrical properties, PET molding coating industry is hard and has a LLDPE molding coating method to make it softer and more bendable. This new method is made of liquid PE fabric melted at high temperature in LLDPE film as shown in FIG. In addition, the process of molding and coating the LLDPE film with the liquid PE on the both sides after the first molding crimping operation, and there is a safe LLDPE molding insulation coating method which does not break even when folded or bent.The liquid PE and LLDPE also have more flexibility. LDPE can be used, and the LLDPE film of the first crimping process is about 10 to 50% thicker than the film of the second crimping process, and the insulation film is applied before molding the PE liquid about 10 to 50% or molding together with the fabric. In addition, it is possible to prevent the leakage of current even when the fabric is stuck in the film during the first crimping process by molding molding with the fabric after molding bonding. .

In the net heating element generated by electrical properties, the urethane film molding coating method is a liquid urethane melted at a high temperature as shown in FIG. Applying acrylic adhesive to the film and coating the matured film with a liquid urethane primary coating on both sides by molding and pressing, where the urethane film of the first crimping process is 10 to 50 than the urethane film of the second crimping process. It is thicker than about% and the current is leaked even if the fabric is embedded in the film during the first crimping process by additionally molding and bonding the insulation film before molding the urethane liquid or molding it together with the fabric. This can be prevented and the result as shown in Figure 12 was obtained through the above process.

The molding insulation method as described above is an important technical feature of the insulation coding Inbar molding method in the net heating element, the molding material is polyethylene, PET, PE, HDPE, LDPE, LLDPE, PVC, urethane, PETG, PS, PP, PSP, It should be understood that there are no restrictions on materials such as PP and silicone.

In addition, in the net heating element generated by electrical characteristics, the urethane forced crimp insulation coating method has a process of forcibly crimping by using a thermal roller. This method blows hot air together with a urethane film and a fabric to the thermal roller as shown in FIG. There is a safe urethane molding insulation coating method without disconnection even when folded or bent as a method of forced compression, hot air is effective to increase the adhesive strength, but may not be used. Here, the urethane film of the first crimping process should be about 10 to 50% thicker than the urethane film of the second crimping process, which prevents the leakage of current by preventing the fabric from getting stuck in the film during the first crimping process. Through the above process to obtain the result as shown in FIG.

In the mesh heating element that is generated by electrical properties, the panel type insulation coating is primarily formed by molding the adhesive on the glass fiber of the mesh structure by mixing functional powders such as ocher, elvan, male, and ceramics with the adhesive having an insulating and hardening component. Secondly, the net heating element is placed and molded with adhesive, and then the glass fiber is put on top and molded with adhesive to dry. The lamination method as shown in Fig. 16 is an important technique for strengthening the durability of the heating element and insulation method. Its purpose is to prevent warpage of panels during drying and to improve its durability. Functional powders such as clay, elvan, male, and ceramics are used for far-infrared radiation and deodorization, which are beneficial to human body. In addition, the panel-type insulation coating prepared as described above was obtained as shown in FIG.

In addition, in the mesh heating element that is generated by electrical characteristics, the polyethylene film forced crimp insulation coating method has a process of forcibly crimping by using a heat flat press. In this method, a polyethylene film is placed on a double-sided crimp heat flat press and a power source is placed thereon. It is a method to insulate small size heating elements such as beds, mats, steamers, heating vests, etc. by placing a mesh heating element with a terminal for supply and putting polyethylene film on the back and forcibly crimping it with a double-sided pressing hot plate press. It is a public law.

As described above, according to the constant temperature resistance (PTC) mesh heating element according to the present invention, in the manufacture of the constant temperature resistance (PTC) mesh heating element, by making a constant temperature resistance impregnation solution to reduce the risk of fire due to overheating prevention, development of the impregnation process It is a very useful invention that has a uniform temperature distribution and at the same time significantly reduces the risk of power failure, such as power supply reinforcement and coating method development, significantly enhances durability and enables selective partial heating by the user.

Claims (12)

In the mesh heating element that is generated by electrical characteristics, the reinforcement of the polar wires for the fabrication of the power source and the fabric for durability reinforcement is made of conductive materials such as gold, silver, copper, stainless steel, stainless steel, nickel, nickel, and the like. Twist the wire 11 to make a single wire (12), and as shown in Figure 3 gathered together to form a continuous fiber on both sides of the woven fabric woven together in the form of a net such as longitudinal, transverse, diagonal As shown in FIG. 4, the shape of the pole line may be two lines (41a, 41b), three lines (42a, 42b), four lines 43, and a plurality of pole lines 44 may be used depending on the intended use. Reinforcement method of pole line, which enables partial heating by + pole line and-pole line which is optional by user In the mesh heating element generated by electrical characteristics, the use of flexible fiber yarns twists a plurality of fiber yarns to form a single yarn 21 as shown in FIG. 2 to increase absorption, and the material absorbs a mixed solution such as cotton and cotton mixed yarns. If the material can be mixed, they can be used mixed with each other, impregnated by mixing the weft or warp, weft and warp yarns of a rigid synthetic resin (52) that is heat-resistant and mixed with nylon, PP, glass fiber yarn, etc. While maintaining the heating temperature of the fabric itself, it functions to adjust the wattage (W) used per unit area, and the simplest rectangular mesh structure in the form of a net in this heating element is ideal, but it is not limited thereto. There is no particularity in various forms such as polygons, and each structure is enlarged in size as shown in FIG. 6 (61) to increase resistance or decrease in size (62). Preparation of the fabric, characterized in that to perform the respective functions which can also adjust the overall watts (W) to each of the mix to perform the function's rigid synthetic resin or sizing of the net form a lower section In the mesh heating element that generates heat by electrical properties, the blending ratio for preparing the mixed liquid is 20 to 80 parts by weight of carbon material, 5 to 40 parts by weight of PVA, 5 to 80 parts by weight of EVA, 5 to 80 parts by weight of binder, and a penetrant. Prepare a mixture of 5 to 20 parts by weight, 2 to 20 parts by weight of dispersant, 2 to 20 parts by weight of antifoaming agent, and 300 to 1000 parts by weight of water. Preparation of a mixed liquid, characterized in that it can be used to increase or decrease appropriately according to each use depending on the magnitude of power supply voltage, power consumption, calorific value, etc. In constant temperature resistance (PTC) mesh heating element, The blending ratio for the preparation of the mixed solution for the constant temperature resistance is 0 to 80 parts by weight of barium titanate (BaTiO3), 0 to 80 parts by weight of carbon material, 5 to 40 parts by weight of PVA, 5 to 80 parts by weight of EVA, and 5 to 80 binders. To prepare a mixed solution of a mixture of parts by weight, 5 to 20 parts by weight of penetrant, 2 to 20 parts by weight of dispersant, 2 to 20 parts by weight of antifoaming agent, and 300 to 1000 parts by weight of water. The mixing ratio of is not fixed, but can be used by appropriately increasing or decreasing according to each application depending on the magnitude of power supply voltage, power consumption, heat generation amount, etc. In the technique of impregnation and drying process for even temperature distribution, the process is performed by impregnating the mesh fabric 81 into the mixed solution (82) as shown in FIG. It is characterized by a process of having a temperature distribution and blowing process (84) to blow a strong wind to remove the blockage of the mixed liquid by the weaving and compacting process, the drying process is the first drying in the drying tank Secondary drying using heat roller (88) through rotational annealing process (812) so that the fabric is evenly dissipated in the gypsum top roller, and pressing process with thermo compression roller (89) to prevent deformation of resistance during coating. Produces the distribution of constant temperature resistance (PTC) mesh heating element or mesh heating element fabric, and the drying process in the drying tank is not limited to the above process, but using the commercially available tenter method and the above process. Impregnation method, characterized in that to obtain the same results In the net heating element generated by electrical characteristics, the molding coating method in the insulation coating step of strengthening durability is a liquid polyethylene-based melted at a high temperature as shown in FIG. After molding and pressing, the uncoated side is coated with an acrylic adhesive on the polyethylene film as a secondary, and the film that is matured by applying the primary coating of the primary film coated with liquid polyethylene on both sides is pressed and coated on both sides so that there is no disconnection. It features a safe polyethylene-based insulation coating method, and the polyethylene film of the primary crimping process is about 10 to 50% thicker than the secondary crimping film and to mold the polyethylene liquid by about 10 to 50% more. Before molding together, the insulation film is additionally molded and bonded and then pressed with the fabric. Molding method, isolated characterized in that the step when the fabric is coated to prevent a current from being embedded in the film leak. In the net heating element generated by electrical properties, the PET molding coating method is applied to the PET film by applying an acrylic adhesive to the maturing process (10b) and then impregnated with a liquid PE (10e, 10c) melted at a high temperature as shown in FIG. After the primary molding compression (10d) work with the fabric (10a), the first uncoated surface of the uncoated surface was once again coated with acrylic adhesive on the PET film in the same process. It is a process of molding and pressing the coating on both sides, and it features a safe PET molding insulation coating method without disconnection even when folded or bent as shown in FIG. 10, wherein the liquid PE can use LDPE to provide more flexibility, and PET film is about 10 ~ 50% thicker than the film of the second compression process, and after insulated film is additionally bonded after molding the PE liquid about 10 ~ 50% or molding together with fabric The first molding molding crimped with the mesh fabric and the first compression crimping process during the first crimping process to prevent the leakage of current even if the fabric is embedded in the film and the coating method characterized in that the result as shown in Figure 11 through the above process Way In the mesh heating element that is generated by electrical characteristics, liquid PE melted at high temperature in LLDPE film at high temperature in the insulation coating process to enhance durability, and then LLDPE film is second liquid after primary molding compression work with fabric. As a process of molding pressing and coating on both sides as PE, as shown in Fig. 10, there is a safe LLDPE molding insulation coating method that does not break or bend even when folded or bent. Here, liquid PE and LLDPE can also use LDPE to give more flexibility, and the first crimping method. The LLDPE film of the process is about 10 to 50% thicker than the film of the second crimping process, and after molding the PE liquid about 10 to 50% more or molding together with the fabric, the insulation film is additionally molded and bonded to the fabric after molding. Insulation molding method characterized in that the coating to prevent the leakage of current even if the fabric is embedded in the film during the first crimping process. In the net heating element generated by electrical characteristics, in the insulation coating process for enhanced durability, after the acrylic adhesive is applied to the urethane film and aged, the first molding together with the fabric with liquid urethane, PE or LDPE melted at high temperature as shown in FIG. After crimping, apply the acrylic film to the urethane film for the second time and apply the film to the both sides by molding and pressing the first coated fabric with liquid urethane on both sides.The urethane film of the first crimping process is the second crimping process. It is 10 ~ 50% thicker than urethane film and 10 ~ 50% more urethane liquid or before insulated with fabric, the insulation film is additionally molded and bonded together with the fabric. It is characterized in that the coating so as to prevent leakage of current even if it is lodged, as shown in Figure 12 through the above process Insulation to get the water characterized in molding method. In the mesh heating element that is generated by electrical characteristics, the urethane forced insulation coating method has a process of forcibly crimping with a thermal roller in the insulation coating process for enhanced durability. There is a safe urethane molding insulation coating method that does not break even when folded or bent as shown in Fig. 14 by forced hot air blowing the fabric together, hot air has the effect of improving the adhesive strength, but do not need to use, urethane of the first crimping process The film is characterized in that the coating method is used to prevent 10 to 50% thicker than the urethane film of the second pressing process and to prevent the fabric from getting stuck in the film during the first pressing process. Insulation coating method, characterized in that to obtain a result. In the mesh heating element that is generated by electrical properties, the panel type insulation coating is primarily formed by molding the adhesive on the glass fiber of the mesh structure by mixing functional powders such as ocher, elvan, male, and ceramics with the adhesive having an insulating and hardening component. Secondly, the mesh heating element is put on, molded with an adhesive, and then put again glass fiber on top of it, molded with an adhesive, and laminated molding coating is a coating method characterized by the lamination method as shown in Fig. 16. Insulation molding method, characterized in that the same result is obtained. In the mesh heating element that is generated by electrical characteristics, the polyethylene film forced crimp insulation coating method is a method of forcibly crimping using a thermal flat plate press. An insulation coating method comprising placing a mesh heating element and then putting a polyethylene film on the back, forcibly crimping with a double-sided compression heat plate press for insulation coating.

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