KR20100087907A - Film heater with improved stability and its manufacturing method - Google Patents

Abstract

PURPOSE: A film heater with improved stability and a manufacturing method thereof are provided to reduce the risk of fire disasters due to electrical hazards by joining a shielding film and an outer cover sequentially on the upper and lower surfaces of a heating part. CONSTITUTION: A film heater comprises a heater(100), a shielding film(130), and an outer cover(150). The heater plays a role of generating heat while being conducted. The heater comprises a first synthesis resin film(110), a first carbon conductive filler layer(111) positioned on the top of the first synthesis resin film, a plurality of copper wires(112) positioned inside the first carbon conductive filler layer, a nonwoven fabric layer(113) covering the top of the copper wires, and a second synthetic resin film(115) positioned on the top of the nonwoven fabric layer.

Description

Planar heating element with improved stability and its manufacturing method

The present invention relates to a planar heating element with improved stability and a method for manufacturing the same, and more particularly, an outer shell which can add flexibility to the shielding film and planar heating element that can reduce the damage of electric fields, magnetic fields and electromagnetic waves and reduce the noise of the planar heating element itself. It can be used for a variety of bedding and clothing that needs flexibility, including, and relates to a planar heating element and improved stability that can reduce the risk of fire due to electrical troubles.

Ordinary planar heating elements that generate electricity by generating electricity are not only sanitary because they do not pollute the air, but are also easy to control their temperature and are silent. It is widely used for heating devices such as houses. In addition, heating devices in commercial buildings such as offices and shops, industrial heating devices such as workshops, warehouses, barracks, and other industrial heating devices, agricultural equipment such as plastic houses and agricultural product drying systems, and melting snow or freezing roads and parking lots In addition to various freeze protection devices that can be prevented, it is widely used for leisure, winter protection, home appliances, anti-fog device of mirror or glass, health supplement, animal husbandry.

In general, the front heating element separates the work into the upper and lower limbs, and after applying heating material to one or both sides, and if it is sufficiently dried, the copper wire called the braided wire in the process of laminating the upper and lower limbs is a pure extrusion coating method. (Extrude Laminating) or dry laminating (Dry Laminating) method using an adhesive, it has been firmly fixed and has been used as a power supply line.

In this process, the work process is mainly to conduct the heating material work first before the heating material work first and then the heating material work and finally the lamination work of the upper and lower limbs.

1 is a cross-sectional view of a conventional planar heating element described in Korean Patent No. 860258.

Referring to FIG. 1, a conventional front planar heating element includes a first synthetic resin film 10 used as a first envelope, and a first carbon conductor containing a carbon conductor located on the first synthetic resin film 10. Layers 11 and a plurality of copper wires 12 which are located inside the first carbon conductor layer 11, the lower side and the left and right sides are completely surrounded by the first carbon conductor layer 11, A second nonwoven fabric layer 13 disposed on the top of the one carbon conductor layer 11 and simultaneously covering two adjacent copper wires 12, and a second conductor including a carbon conductor positioned on the nonwoven fabric layer 13. And a second synthetic resin film 15 positioned on the second carbon conductive layer 14 and used as a second sheath.

However, the conventional planar heating element is weak and stiffly formed due to its nature, so that play may occur between the copper wire 12 and the contact surface due to external impact such as stepping on a person, repeated bending or folding, and in this case, a curved copper wire (12) There is a risk of fire due to increased resistance in the vicinity. This has been the biggest obstacle to the popularization of planar heating element.

In addition, due to the problems of the conducting wire as described above, the front surface heating element used the outer material as a hard material, such as PET (poly ethylene terephtalate) or OPP (oriented poly propylene) film, the surface heating element is a limited space, such as a flat floor There was a problem that can only be used.

In addition, the conventional planar heating element is required to solve the problem as a lot of electric fields, magnetic fields and electromagnetic waves harmful to the human body is generated.

The present invention has been made to solve the above problems, can be used in various beddings and clothes that require flexibility, can prevent damage caused by electric fields, magnetic fields and electromagnetic waves, and reduce the risk of fire caused by electrical problems It is an object of the present invention to provide a planar heating element having improved stability and a method of manufacturing the same.

The planar heating element of the present invention for realizing the object as described above, the heat conductive portion is a carbon conductor, a non-woven fabric and a synthetic resin film is crimped with copper wires interposed therebetween to generate heat when energized; A shielding film formed on upper and lower surfaces of the heating unit to block electromagnetic waves and magnetic fields generated in the heating unit; It is characterized in that it is configured to include; the outer shell is bonded to the surface of the shielding film to add flexibility so that the heating portion can be bent smoothly.

In this case, the heat generating unit is located in the first synthetic resin film, the first carbon conductive layer located on the first synthetic resin film and containing the carbon conductor, and the first carbon conductive layer, but the lower side and the left and right sides. Is a plurality of copper wires completely surrounded by the first carbon conductor layer, a nonwoven fabric layer positioned on the first carbon conductor layer and simultaneously covering the upper side of the copper wire, and a second synthetic resin located on the nonwoven fabric layer. It is characterized by including a film.

In addition, the nonwoven fabric layer and the second synthetic resin film includes a second carbon conductive layer containing a carbon conductor is further formed.

In addition, the outer shell is characterized in that the nonwoven fabric, cotton or nylon material.

In addition, the shell is characterized in that formed in 10 ~ 200g / ㎡.

In addition, a cut line is formed on the outer surface of the outer surface so that a plurality of planar heating elements can be divided and formed according to a product use, and the cut line is formed to maintain an empty space of at least 1 to 2 cm at the end of the shielding film. do.

A method of manufacturing a planar heating element, comprising: forming a first carbon conductor layer on one surface of a first synthetic resin film; Squeezing after aligning the copper wire and the nonwoven fabric layer in the order of the first carbon conductor layer; Applying an adhesive to the upper portion of the nonwoven fabric layer and then bonding the second synthetic resin film to complete the heating part; Forming a shielding film on the upper and lower surfaces of the heat generating part to laminate and print a carbon conductor to block electromagnetic waves and magnetic fields generated from the heat generating part; And adding flexibility to the heat generating unit by bonding the outer surface of the nonwoven fabric, cotton or nylon material to the surface of the shielding film, respectively.

A method of manufacturing a planar heating element, comprising: forming a first carbon conductor layer on one surface of a first synthetic resin film; Squeezing after aligning the copper wire and the nonwoven fabric layer in the order of the first carbon conductor layer; Laminating and printing a second carbon conductor layer on the nonwoven fabric layer; Applying an adhesive to the upper portion of the second carbon conductive layer and then bonding the second synthetic resin film to complete the heat generating part; Forming a shielding film on the upper and lower surfaces of the heat generating part to laminate and print a carbon conductor to block electromagnetic waves and magnetic fields generated from the heat generating part; And adding flexibility to the heat generating unit by bonding the outer surface of the nonwoven fabric, cotton or nylon material to the surface of the shielding film, respectively.

The planar heating element with improved stability according to the present invention having the above-described configuration and a method of manufacturing the same can be used in various beddings and clothes that require flexibility by sequentially joining the shielding film and the shell on the upper and lower surfaces of the heating part, and can be used for electric and magnetic fields. And it can block the electromagnetic waves, it can reduce the risk of fire due to electrical troubles.

In addition, it is possible to manufacture a product of DC 40V or less as needed to have an international competitiveness.

Hereinafter, the configuration and operation of the preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings.

It should be noted that in the following description, only parts necessary for understanding the operation according to the present invention will be described, and descriptions of other parts will be omitted so as not to distract from the gist of the present invention.

2 is a cross-sectional view showing the internal structure of the planar heating element according to the present invention, Figure 3 is a cross-sectional view showing another embodiment of the planar heating element according to the present invention.

Referring to FIG. 2, the planar heating element having improved stability according to an exemplary embodiment of the present invention includes a heat generating unit 100, a shielding film 130, and an outer shell 150.

Each of the configurations of the present invention will be described below.

The heat generating part 100 is a carbon conductor, a non-woven fabric and a synthetic resin film is crimped with the copper wire 112 interposed therebetween, and serves to generate heat during energization, and the components forming the heat generating part 100. Is not limited.

In the first embodiment, the heat generating unit 100 is the first synthetic resin film 110, the first carbon conductive layer 111 located on the first synthetic resin film 110 and containing a carbon conductor and And a plurality of copper wires 112 positioned inside the first carbon conductor layer 111 and completely surrounded by the first carbon conductor layer 111 on the lower and left and right sides thereof, and the first carbon conductor layer ( 111) a non-woven fabric layer 113 positioned on the upper portion and simultaneously covering the upper side of the copper wire 112, and a second synthetic resin film 115 located on the upper portion of the nonwoven fabric layer 113.

In the second embodiment, as shown in FIG. 3, the heat generating part 100 is formed of a carbon conductor between the nonwoven fabric layer 113 and the second synthetic resin film 115 to further improve thermal conductivity. The second carbon conductor layer 114 may be further included.

The shielding film 130 is formed of carbon conductors on the upper and lower surfaces of the heating part 100, and the shielding film 130 effectively blocks electric fields, magnetic fields, and electromagnetic waves generated by the heating part 100.

For reference, the carbon used in the shielding film 130 has various uses and characteristics, and carbon has advantages of far infrared rays, not just a concept of heat, and absorbs electromagnetic waves, deodorizes, absorbs heavy metals, generates far infrared rays, and controls humidity. It is effective in removing germs, pesticide effect, acidification prevention and anion generation.

In addition, the principle that the carbon conductor used in the shielding film 130 blocks an electric field, a magnetic field, and electromagnetic waves is as follows.

In general, electric and magnetic fields and electromagnetic waves are generated on the surface of all electric appliances, and the damages appear in various forms. For example, they appear in the form of static electricity when using bedding such as noise of a communication device, a surface of an electric appliance, or a mat. In this case, it is common practice to connect an electric field or a magnetic field appearing on the surface of an electric appliance through a grounding wire so that a leakage current flows to the ground (ground), or by connecting a neutral wire and removing it.

There are active wires (+ wires) and neutral wires (-wires) in the electricity. In countries where active wires and neutral wires are not distinguished as in Korea, the law sets a separate ground wire to be used.

However, in Taiwan and elsewhere, the neutral wire is made into a separate plug so that it is always connected. The reason is that all electric and magnetic fields can be removed by connecting with neutral wires without distinguishing separate earth wires from plugs.

As described above, the shielding film 130 of the present invention applies a carbon conductor to the surface of the heat generating part 100 to sufficiently conduct electricity, and then connects to the earth wire or the neutral wire by using an electric wire, thereby generating the heat generating part ( The electric field, the magnetic field, and the electromagnetic waves generated from the surface of 100) can be removed.

For example, the power of electricity generated from the surface of the heat generating unit 100 may vary depending on the thickness of the insulator, but in severe cases, up to 75% of the incoming power may be generated. In other words, when 220V of electricity is connected, more than 160V of power is generated on the surface in severe cases. Therefore, when the shielding film 130 is formed on the surface of the heat generating part 100 and the wire is connected to the ground wire or the neutral wire of the plug, the power generated from the surface of the heat generating part 100 is reduced to 1V or less. And almost all are erased.

The shielding film 130 is made by mixing 15 to 17% by weight of carbon powder, 1 to 2% by weight of germanium, 4 to 5% by weight of coagulant, 20 to 30% by weight of polyurethane resin, and 50 to 60% by weight of thinner. As the thinner, esters such as ethyl acetate or ketones (solvents), alcohols such as ethanol, toluene, naphtha (diluent) and the like are used.

On the other hand, the outer shell 150 is bonded to the surface of the shielding film 130, respectively, to add flexibility so that the heating unit 100 can be bent smoothly, the outer shell 150 is heat generated from external impact and high temperature In order to protect the part 100, a material such as a flexible nonwoven fabric, cotton, or nylon having strength and heat resistance is used.

In this case, the shell 150 is preferably formed in 10 ~ 200g / ㎡. That is, when the thickness of the outer shell 150 is 10g / m 2 or less, the flexibility of the planar heating element is reduced and becomes stiff, and the poly-based film is difficult to use because of its high noise due to its properties.

When the thickness of the outer shell 150 is formed to be 200 g / m 2 or more, the planar heating element may have flexibility, but becomes too thick, which makes it difficult for the manufacturer to handle.

The outer shell 150 can flexibly respond to repeated bending or folding of the planar heating element to absorb the noise generated from the planar heating element and to reduce the risk of fire due to electric troubles.

Therefore, the planar heating element can be applied to products such as bedding, clothing, and automobile seats that require some softness.

Figure 4 is an embodiment for producing a planar heating element according to the present invention.

Referring to FIG. 4, the planar heating element according to the present invention may be formed in different sizes (a × b) according to various product uses such as mats or cushions, and the planar heating elements may be manufactured at a time to produce a plurality of planar heating elements at once. The cutting line 170 is formed in the horizontal or vertical direction.

At this time, the cutting line 170 should be formed at the ends of the heat generating part 100 and the shielding film 130 to ensure the empty space (c1) (c2) of at least 1 ~ 2cm in the horizontal or vertical direction to the planar heating element When cut and manufactured into a product, it is possible to prevent electrical troubles.

If the heat generating part 100 and the shielding film 130 are formed without leaving the empty spaces c1 and c2 of the planar heating element, the heat generating part 100 and the shielding film 130 respectively flow in the cut and use of the planar heating element. As electricity passes through each other, sparks are generated.

Then, the planar heating element manufacturing process of the present invention having the above configuration will be described with reference to FIG. 5.

Here, the planar heating element according to the present invention will be described by taking an example in which both the first carbon conductor layer 111 and the second carbon conductor layer 114 are included.

5 is a flowchart illustrating a manufacturing process of the planar heating element according to the present invention.

First, the first carbon conductive layer 111 is formed on one surface of the first synthetic resin film 110 (S11).

After aligning in the order of the copper wire 112 and the nonwoven fabric layer 113 on the upper portion of the first carbon conductor layer 111 (S13).

The second carbon conductive layer 114 is laminated and printed on the nonwoven fabric layer 113 (S15).

After the adhesive is coated on the second carbon conductive layer 114, the second synthetic resin film 115 is bonded to complete the heat generating part 100 (S17).

Thereafter, a carbon conductor is laminated and printed on upper and lower surfaces of the heat generating part 100 to form a shielding film 130 that blocks electromagnetic waves and magnetic fields generated in the heat generating part 100 (S19).

Then, by attaching a non-woven fabric, cotton or nylon outer shell 150 to the surface of the shielding film 130, respectively, and adding flexibility so that the heat generating unit 100 can be bent smoothly (S21).

In the above, the present invention has been shown and described for the manufacturing process of the planar heating element as a specific preferred embodiment, but the present invention is not limited to the above embodiments and the technology to which the present invention belongs without departing from the technical spirit of the present invention Of course, various changes and modifications can be made by those skilled in the art.

1 is a cross-sectional view showing the internal structure of a conventional planar heating element,

2 is a cross-sectional view showing the internal structure of the planar heating element according to the present invention;

3 is a cross-sectional view showing another embodiment of the planar heating element according to the present invention;

Figure 4 is an embodiment for producing a planar heating element according to the present invention,

5 is a flowchart illustrating a manufacturing process of the planar heating element according to the present invention.

<Description of the symbols for the main parts of the drawings>

100: heat generating unit 110: first synthetic resin film

111: carbon conductor layer 112: copper wire

113: nonwoven fabric layer 114: second carbon conductor layer

115: second synthetic resin film 130: shielding film

150: jacket 170: cutting line

Claims (8)

Carbon heater, non-woven fabric and synthetic resin film is pressed across the copper wire and generates heat when energized; A shielding film formed on upper and lower surfaces of the heating unit to block electromagnetic waves and magnetic fields generated in the heating unit; The outer surface is bonded to the surface of each of the shielding film to add flexibility so that the heating portion can be bent smoothly; Planar heating element with improved stability, comprising a. The method of claim 1, The heat generating part may include a first carbon resin layer, a first carbon conductor layer positioned on the first synthetic resin film and containing a carbon conductor, and positioned inside the first carbon conductor layer. A plurality of copper wires completely surrounded by a first carbon conductor layer, a nonwoven fabric layer positioned on the first carbon conductor layer and covering the upper side of the copper wire at the same time, and a second synthetic resin film located on the nonwoven fabric layer. Planar heating element with improved stability, characterized in that configured to include. 3. The method of claim 2, The planar heating element with improved stability including a second carbon conductor layer containing a carbon conductor further formed between the nonwoven fabric layer and the second synthetic resin film. The method of claim 1, The outer shell is a planar heating element with improved stability, characterized in that the nonwoven fabric, cotton or nylon material. The method according to claim 1 or 4, The shell is a planar heating element with improved stability, characterized in that formed in 10 ~ 200g / ㎡. The method of claim 1, A cut line is formed on the outer surface of the shell so that a plurality of planar heating elements can be divided into a plurality of planar heating elements, and the cut line is formed to maintain an empty space of at least 1 to 2 cm at the end of the shielding film. Planar heating element with improved stability. Forming a first carbon conductive layer on one surface of the first synthetic resin film; Squeezing after aligning the copper wire and the nonwoven fabric layer in the order of the first carbon conductor layer; Applying an adhesive to the upper portion of the nonwoven fabric layer and then bonding the second synthetic resin film to complete the heat generating portion; Forming a shielding film on the upper and lower surfaces of the heat generating part to laminate and print a carbon conductor to block electromagnetic waves and magnetic fields generated from the heat generating part; Bonding the outer surface of the non-woven fabric, cotton or nylon material to the surface of the shielding film, respectively, adding flexibility to the heat generating portion; Method of manufacturing a planar heating element with improved stability comprising a. Forming a first carbon conductive layer on one surface of the first synthetic resin film; Squeezing after aligning the copper wire and the nonwoven fabric layer in the order of the first carbon conductor layer; Laminating and printing a second carbon conductor layer on the nonwoven fabric layer; Applying an adhesive to the upper portion of the second carbon conductive layer and then bonding the second synthetic resin film to complete the heat generating part; Forming a shielding film on the upper and lower surfaces of the heat generating part to laminate and print a carbon conductor to block electromagnetic waves and magnetic fields generated from the heat generating part; Bonding the outer surface of the non-woven fabric, cotton or nylon material to the surface of the shielding film, respectively, adding flexibility to the heat generating portion; Method of manufacturing a planar heating element with improved stability comprising a.

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