KR20110094174A - Method for manufacturing ptc film heater by roll to roll with thin metallic etched electrodes - Google Patents

Abstract

PURPOSE: The electrical conductor having the resistance which the PTC generation of heat heating manufacturing process of film using the metallic foil etching electrode is variable according to temperature is used. The possibility of the fire is reduced. CONSTITUTION: The metallic foil is attached in the insulating film. The metallic foil is selected between Cu or Al. It etches in the film adhered as described above to the arbitrary pattern and the circuit electrode is formed. The PTC carbon pace frame is printed. It possibles with the necessary length cutting, the PTC generation of heat film is manufactured with the roll form.

Description

Method for manufacturing PTC film heater by roll to roll with thin metallic etched electrodes

The present invention relates to a film-type planar heating element, and more specifically, to save electric energy due to the relative decrease in power consumption compared to a general planar heating element heating film, and to generate heat quickly and at a low atmospheric temperature in a cold or cold season. Unlike a heating element heating film, it is a method of manufacturing an environment-friendly planar heating element heating film according to the high energy use, which lowers the possibility of fire due to local overheating at high temperature during PTC heating.

Among PTC heating film, those without PTC characteristic have low resistance of heating element, so it is not easy to control the temperature during continuous current drawing, and most of them print pastes mixed with silver powder or silver coated copper powder with electrode and have metal thin film type on it. Due to the form of attaching the booster, there is a disadvantage that the manufacturing process is complicated and expensive.

In addition, in the case of a film-like planar heating element to which PTC carbon paste is applied, even if a silver powder or a silver coated powder paste electrode is used or a metal thin film etching electrode is used, a fragmentary single piece of a certain length is generally used. This is because of the current production process constraints that the printing of silver powder or silver coated powder or the etching processing form of the metal thin film electrode is limited to a certain size.

Therefore, by removing or combining the constraints in each production process to produce a continuous heating roll type PTC heating element heating film as shown in <Fig. 1> to <Fig. 8>.

In the case of the conventional planar heating element heating film, the electrode spacing is determined by the film width produced because the electrode of the incoming current is present at both ends of the film.

In case of carbon paste for general planar heating element, the electric conductivity is formed after printing and drying (the electric resistance is constant). The electrode spacing does not significantly affect the heat generation. However, in the case of PTC carbon paste, the resistance increases when the temperature rises, and the resistance decreases when the temperature decreases, and the electrical conductivity changes according to the heating temperature. Therefore, if the electrode spacing is relatively wide, the electrical conductivity of the heat generating layer itself is not uniform during heat generation, resulting in low heat generation efficiency due to the difference in heat generation temperature.

Regarding the metal thin film etching electrode, the roll-type processing required in the heating film sector was not applied due to the technology generalized in the PCB industry or the characteristics of the industry. In addition, although the PTC surface heating element is partially produced by a single part etching process, no roll-type metal thin film etching electrode film is applicable to the heating film sector.

It is a problem of the present invention to produce a PTC planar heating element that is applied to a fragmentary field as a roll type heating film capable of a continuous process due to the above disadvantages.

The key to solving this problem lies in the production of metal thin film etching films in the form of rolls.

To this end, as shown in FIG. 2, the manufacturing process of the PTC heating element heating film in the form of a continuous process roll for the purpose of the present invention was solved by reconfiguring and combining the etching process used in the existing single product production into a continuous process form.

In this process, the booster process of printing silver powder or silver plated copper powder paste, which is a high cost and low efficiency in the conventional general heating film production process, may be omitted.

According to the present invention, it is possible to manufacture a heating film that can realize the maximum PTC characteristics that a general heating film does not have.

The PTC characteristic means that the electric conductor does not have a constant resistance and the resistance is variable according to the temperature, so that at low temperatures, it has high conductivity with low resistance, and at high temperatures, it has low conductivity with high resistance.

When the heating film is manufactured using these PTC characteristics, the heating effect felt by the user is maximized by the rapid temperature rise in the cold temperature or the cold season where the heating is required, and the general heating film according to the continuous heat generation and temperature rise due to the characteristics of the heating. It is possible to exclude the possibility of fire due to local heating, which is a disadvantage, and save more energy than general heating film when comparing the total used electric power.

The description of the drawings is replaced by the specific contents.
<Figure 1> Annealing process of insulating film laminated with metal thin film
1-1 Insulation film laminated with metal thin film
1-2 Annealing treatment to prevent heat deformation
1-3 Winding Annealed Insulation Film
<Figure 2> Electrode circuit pattern etching process
2-1 Electrode Circuit Pattern Etch Register Printing (Silk Screen or Gravure Printing)
2-2 Heat Dry or UV Exposure Dry
2-3 Etching tanks that corrode metal thin film areas other than the printed areas
2-4 Printed Etch Register Film Stripping Bath
2-5 washing tank
2-6 heat drying
2-7 Metal Thin Etching Electrode Film Roll Winding
<Figure 3> Example of etched electrode circuit pattern
3-1 Metal Thin Etching Electrode Insulating Film Roll
3-2 Example of Surface of Etched Electrode Circuit
<Figure 4> PTC carbon paste heating layer printing process on etching electrode film
4-1 PTC carbon paste printing on etching electrode insulation film (silk screen or gravure printing)
4-2 Heat Drying
4-3 Roll Winding
<Figure 5> Example of printing PTC carbon paste heating layer on etching electrode film
<Figure 6> Example of detailed cross section of printed surface (not shown adhesive layer of metal film)
6-1 Insulation Film (PET, PIN, or PI Film)
6-2 etching electrode (Cu or AL); Current electrodes + and- respectively
6-3 PTC Carbon Paste Printing Heating Layer
<Figure 7> Laminating process of insulating film for printed heating layer surface protection
7-1 Insulation film (PET, PIN, or PI film) or laminated double-sided tape
7-2 Copper or Tin Plated Copper Booster
7-3 PTC Heating Layer Printed Film
7-4 Lamination Process
7-5 Roll Winding
<Figure 8> A detailed example of the surface of the finished PTC heating element heating film
8-1 Insulation Film (PET, PIN, or PI Film)
8-2 Etching Electrode (Cu or AL)
8-3 PTC Carbon Paste Heating Layer
8-4 Metal Booster (Copper or Tin Plated Copper)
8-5 Surface Protection Insulation Film (PET, PIN, or PI Film) or Insulation Double Sided Tape

As shown in <Figure 1>, a heat-extruded insulating film (PET, PIN, or PI film) with a thin metal film is used for heating film. Since there may be deformation due to the difference in thermal expansion coefficient of the film, annealing treatment is first performed to prevent thermal deformation. Annealing is about 2 to 15 minutes between 100 to 180 degreeC.

In order to etch the electrode circuit pattern on the annealed metal thin film insulating film, as shown in Fig. 2, first, according to the environment in which the PTC heating film is used, the electrode circuit pattern is designed according to the operating voltage and power. The UV curing etch register is silkscreened or gravure printed (Fig. 2-1). The etching resist printed as described above is etched after heat drying or UV exposure drying (Fig. 2-2), depending on the curing type, and etching parts other than the printed circuit pattern in the etching bath in which the acid etching agent is diluted (Fig. 2-3). In order to neutralize the film removal and etching site | part of an etching register using alkaline aqueous solution (FIG. 2-4). It is again washed in a wash bath (Fig. 2-5) and the surface is dried (Fig. 2-6).

This process results in a metal thin film etch electrode film in which only the intended electrode circuit pattern remains appropriate for the voltage and force used. (Fig. 3-2)

The etching electrode film processed in this manner and wound in a roll form is subjected to the same printing process as in the conventional silk screen printing or gravure printing as shown in FIG.

However, according to the object of the invention of this manufacturing method to use the above etch electrode film, the printing ink uses PTC carbon paste.

The printed pattern of the PTC carbon paste heating layer is as shown in the example of <Fig. 5> according to the usage environment and use of the heating and heating film, such as <Fig. 5-1>, <Fig. 5-2>, and <Fig. 5-3>. Print with pattern

Looking at the cross section of the printed <Fig. 5-1> film up to this process it can be seen that the same as <Fig. 6>. (The adhesive layer of the metal thin film is not shown.)

Films printed and dried up to the PTC heating layer undergo a aging stabilization step of 24 to 48 hours at room temperature in relation to the properties of the PTC carbon paste.

As shown in <Fig. 7>, the insulating film (PET, PIN, or PI film) or insulating double-sided tape (drawing paper) may be used depending on the environment to be used for protecting the surface of the film on which the PTC heating layer is printed (Fig. 7-3). 7-1) Join.

In this process, copper foil or tin-plated copper foil is used as a booster for stable flow of current and prevention of electric trouble on the current induction circuit electrodes formed on both sides of the film, and to facilitate contact terminal attachment with the electric lead wire during film construction. And insert it as (Fig. 7-2). (Fig. 7-4)

The detailed form of the completed PTC planar heating element heating film after the process is as shown in <Fig. 8>, which is intended to specifically illustrate an example of the present patent, and is not limited to the form of <Fig. 8>.

Applicable

Claims (3)

After etching the metal film (Cu or Al) laminated on the insulating film (PET, PIN, or PI film) in an arbitrary pattern to form a circuit electrode, PTC carbon face printing (silk screen or gravure printing) Heating method of heating film of PTC plane heating element manufactured in roll shape to be cut to required length The method of etching the electrode circuit pattern according to claim 1, wherein the electrode circuit pattern can be continuously processed in a roll-packed state of the metal thin film insulating film as shown in FIG. Manufacturing method of forming a booster directly from copper foil or tin plated copper foil by omitting the booster layer printed with silver powder or silver plated copper powder paste on the current induction electrode formed by etching processing on both sides of the heating film.

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