RU2401518C1 - Resistor with positive temperature coefficient - Google Patents

Abstract

FIELD: electricity.

SUBSTANCE: resistor with positive temperature coefficient (PTC) contains at least one composition with PTC which contains at least one resin and at least two conducting materials, and at least conducting materials contain at least two different conducting materials. At least one composition with PTC can contain the first composition with PTC which contains the first resin and at least one first conducting material, and the second composition with PTC which is compounded with the first PTC composition and contains the second resin and at least one second conducting material. At least one first conducting material at least partially differs from at least one second conducting material. One of the first resin and the second resin can contain reactant resin and chemically active resin which joins with reactant resin. Resistor with PTC can contain additive of fire-retarding composition. Resistor with PTC can contain fluid-resistant resin.

EFFECT: design simplification, improvement of PTC characteristics, increase in flexibility.

88 cl, 32 dwg

Description

FIELD OF TECHNOLOGY

The present invention relates to a resistor having a PTC characteristic (positive temperature coefficient), the present invention relates to a polymer resistor composition with an excellent PTC characteristic and a highly reliable sheet heating element using this polymer resistor composition. The sheet heating element is so flexible that it can be mounted on the surface of any shape of a household appliance.

BACKGROUND

According to the PTC characteristic, when the temperature rises, the resistance rises with it. A sheet heating element having such a PTC characteristic has self-regulation of the temperature of the heat that it emits. Prior to this, the resistor was used in the fuel element of the design of such a sheet heating element. This resistor was formed from a resistor ink consisting of a base polymer and a conductive material dispersed in a solvent.

This resistor printing ink is printed on a base material forming a heating element. The ink is dried and then fired to form a sheet-shaped resistor (for example, see [1], [2] and [3]). This resistor emits heat by conducting electricity. The conductive material used in this type of resistor is typically carbon black, metal powder, graphite, and the like. Crystalline resin is typically used as the base polymer. A sheet heating element formed from such materials exhibits a PTC characteristic.

FIG. 1A is a plan view of a prior art sheet heating element described in [1]. To simplify the description, the drawing shows a transparent view of the internal structure of the heating element. FIG. 1B is a sectional view taken along line 1B-1B of FIG. 1A. As shown in FIG. 1A and FIG. 1B, the sheet heating element 10 is formed of a substrate 11, a pair of electrodes 12, 13, a polymer resistor 14, and a coating material 15. The electrodes 12, 13 form a comb-like shape. The substrate 11 is a material with electrical insulating properties, and is formed from resin and, for example, is a polyester film.

The electrodes 12, 13 are formed by printing a conductive printing ink, such as silver paste, on a substrate 11, and then allowing it to dry. The polymer resistor 14 makes electrical contact with the comb-shaped electrodes 12, 13 and is electrically powered by these electrodes. The polymer resistor 14 has a PTC characteristic. The polymer resistor 14 is formed of polymer resistor printing ink, and this printing ink is printed and dried in place to create electrical contact with the electrodes 12, 13 on the substrate. The coating material 15 is formed from the same type of material as the substrate 11, and protects the electrodes 12, 13 and the polymer resistor 14 by coating them.

In cases where the polyester film is used as the substrate 11 and the coating material 15, the hot-melt resin 16, such as modified polyethylene, adheres to the coating material 15 in advance. Then, along with the application of heat, the substrate 11 and the coating material 15 are compressed. Accordingly, the substrate 11 and the coating material 15 are connected. The coating material 15 and the hot-melt resin 16 isolate the electrodes 12, 13 and the polymer resistor 14 from the external environment. For this reason, the reliability of the sheet heating element 10 is maintained for a long time.

FIG. 2 shows an abbreviated cross-sectional view of a structure of a device that imposes a coating material 15. As shown in the drawing, a laminator 22 formed by two hot rollers 20, 21 performs thermal compression. In the process, the substrate 11, on which the electrodes 12, 13 and the polymer resistor 14 are formed in advance, and the coating material 15, on which the hot-melt resin 16 is applied in advance, are placed on top of each other and fed into the laminator 22. They are subjected to thermal compression using hot rollers 20 , 21, thereby forming the sheet heating element 10 as a unit.

The polymer resistor formed in this way has a PTC characteristic, and the resistance value increases due to temperature rise, and when a certain temperature is reached, the resistance value increases significantly. Since the polymer resistor 14 has a PTC characteristic, the sheet heating element 10 has a temperature self-regulating function.

[2] disclosed a composition with PTC formed from an amorphous polymer, particles of a crystalline polymer, conductive carbon black, graphite, and an inorganic filler. The PTC formulation is dispersed in an organic solvent to create a printing ink. Then, the ink is printed on a resin film provided with electrodes to make a polymer resistor. Additionally, heat treatment is performed to achieve crosslinking (formation of compounds with transverse intermolecular bonds). A resin-based film is applied to the polymer resistor as a protective layer, thereby completing the sheet heating element. This sheet heating element according to [2] has the same PTC heat release characteristic as in [1].

FIG. 3 shows a cross-sectional view of another sheet heating element of the prior art described in [3]. As shown in FIG. 3, the sheet heating element 30 has a flexible substrate 31. Electrodes 32, 33 and a polymer resistor 34 are sequentially applied to this flexible substrate 31 by printing. Then, a flexible coating layer 35 is formed on top of this. The substrate has a gas barrier property and a waterproof property. Substrate 31 comprises a nonwoven polyester fabric including long fibers, and a hot glue film, such as a polyurethane type, is attached to the surface of this nonwoven polyester fabric. The substrate 31 may be impregnated with a liquid, such as a polymer resistor printing ink.

The coating layer 35 contains a non-woven polyester material including long fibers, and a hot-melt adhesive film, such as a polyurethane type, is attached to the surface of this non-woven polyester material. The coating layer 35 also has a gas barrier property and a water resistant property. The coating layer 35 is adhered to the substrate 31, completely covering the electrodes 32, 33 and the polymer resistor 34. The sheet heating material 30 according to Patent Document 3 is completely formed of six layers. This sheet heating element according to [3] also has the same PTC heat release characteristic as in [1].

FIG. 4A and FIG. 4B are drawings showing a mechanism in which a PTC characteristic appears in a polymer resistor 34. The PTC resistor of FIG. 4A and FIG. 4B has particulate conductors 40, such as carbon black. FIG. 4A shows a condition under room temperature conditions, and FIG. 6B shows a state when the temperature rises.

As shown in FIG. 4A, within the polymer resistor 34, the particulate conductors 40 create mutual point contact in the resin composition 41, thereby forming conductive paths. When a current is applied to the electrodes 32, 33, the current flows through the conductors 40 of the particulates that create a point contact, so that the polymer resistor 34 is heated. The resin composition 41 expands due to the fact that the polymer resistor 34 is heated. Thus, as shown in FIG. 4B, the conductors 40 of the particles are removed from each other, breaking contact, so that the resistance value increases along with the temperature. In other words, the polymer resistor 34 exhibits a characteristic of a positive temperature coefficient of resistance.

FIG. 5 shows a PTC characteristic of a polymer resistor 34. The horizontal axis of FIG. 5 shows the resistivity (resistance per unit length) of the polymer resistor 34. The ratio of the resistivity of the polymer resistor 34 at 50 ° C and at 20 ° C was determined experimentally. The vertical axis of FIG. 5 shows the coefficient of change of resistivity (R50 / R20). Similar experiments were carried out with a change in the type of resin in the polymer resistor 34, the type of conductor 40, and the compositional ratio of the composition 41 based on the resin and the conductor 40 to determine the resistivity changes, and these coefficients were plotted in FIG. 5. It is usually the case that resistors with high resistivity coefficients have excellent PTC characteristics. As shown in FIG. 5, experiments where the compositions are changed have shown that the coefficients of change in the resistivity of the prior art polymer resistors 34 are all 2 or less.

In the prior art sheet heating element 10 according to [1] and [2], a rigid material such as a polyester film is used as the substrate 11. In addition, the prior art heating element 10 has a five-layer structure formed from the substrate 11, comb electrodes 12, 13 printed on it, a polymer resistor 14 and a coating material 15 having an adhesive layer applied thereon. As its thickness increases, the sheet heating element 10 loses its flexibility. When such a sheet heating element 10 lacking in flexibility is used as a car seat heater, the passenger seat comfort is reduced. When such a sheet heating element 10 lacking in flexibility is used as a steering wheel heater, the feeling of a comfortable grip is reduced.

Since the heating element 10 is in the form of a sheet, if a load is applied to a portion of its surface, for example, when it is used as a car seat heater and the passenger sits on it, the force extends to the heating element as a whole, and the heating element 10 changes shape. Typically, the closer to the edge of the heating element 10, the greater the amount of deformation. Thus, folds are formed unevenly on the heating element. Cracks in the comb-shaped electrodes 12, 13 and the polymer resistor 14 may be the result of these folds. Accordingly, it is assumed that such a heating element should have a low durability.

The polyester sheets used in the substrate 11 and in the coating material 15 do not have any ventilation properties. Thus, when the heating element 10 is used in the car seat heater or in the steering wheel heater, the liquid released by the passenger or the driver easily accumulate in them. Driving or riding for a long time becomes very uncomfortable.

On the other hand, in the case of the sheet heating element 30 according to Patent Document 3, the electrodes 32, 33, the polymer resistor 34, the substrate and the cover layer are flexible, therefore, when used in a car seat heater or a steering wheel heater, it is convenient to sit or feel the steering wheel. However, since the sheet heating element 30 is formed of six layers, there are drawbacks that labor productivity is low and cost is high.

As shown in FIG. 5, the resistivity value of the sheet heating element of the prior art is 2 or less. At this level of PTC performance, energy efficiency can in no way be considered good. There is also the disadvantage that the temperature does not rise quickly. A method for improving the PTC characteristics of the polymer resistor 34 is to increase the mass of the conductor 34. However, when the mass of the conductor 34 rises, the polymer resistor 34 itself becomes stiff and inelastic. Thus, it is not possible to stably form a film of polymer resistor 34 as thin as several tens of micrometers. Moreover, the film itself does not have any flexibility, and there is a problem that cracks form during processing, making it difficult to form as a film.

SUMMARY OF THE INVENTION

The present invention solves these problems of the prior art and aims to provide a sheet heating element with excellent flexibility, durability and reliability, as well as low production costs. When the sheet heating element of the present invention is used in a car seat heater or in a steering wheel heater, the passenger feels comfortable when sitting on the seat, and the driver feels comfortable when touching the steering wheel.

A PTC resistor according to the present invention contains at least one PTC composition, which contains at least one resin and at least two conductive materials. At least two conductive materials comprise at least two conductive materials different from each other. At least one PTC compound may contain a first PTC compound that contains a first resin and at least one first conductive material, and a second PTC compound that is compounded with a first PTC compound and contains a second resin and at least one second conductive material. At least one first conductive material is at least partially different from at least one second conductive material. One of the first and second PTC compounds can form clusters that are distributed within the other of the first and second PTC compounds.

One of the first and second PTC compositions may be contained in a PTC resistor with a content of 20-80 wt.%, Preferably 30-70 wt.% Or optimally 40-60 wt.%.

One of the first resin and the second resin may contain a reagent resin and a reactive resin that is crosslinked with the reagent resin. The reagent resin may contain a modified olefin resin, which may contain an ethylene ester type copolymer. Examples of the ethylene ester type copolymer used in the reagent resin are ethylene / vinyl acetate copolymer, ethylene / ethyl acrylate copolymer, ethylene / methyl methacrylate copolymer, ethylene / methacrylic acid copolymer and ethylene / butyl acrylate copolymer.

The reactive resin may be contained in said one of the first resin and the second resin with a content of 1-20 wt.% Or preferably 1-10 wt.%.

The reagent resin reacts with the reactive resin and forms a crosslinked structure inside. For this purpose, the reagent and chemically active resins may contain different components selected from the group consisting of carboxyl groups, carbonyl groups, hydroxyl groups, ester groups, vinyl groups, amine groups, epoxy groups, oxazoline groups and maleic anhydride groups.

The other of the first resin and the second resin may contain components selected from the group consisting of carboxyl groups, carbonyl groups, hydroxyl groups, ester groups, vinyl groups, amine groups, epoxy groups, oxazoline groups and maleic anhydride groups. The other of the first resin and the second resin are not reacted with the reactive resin and do not contain a crosslinking structure.

At least one of the first and second resins may contain a thermoplastic elastomer. The thermoplastic elastomer may comprise at least one of an olefin-based thermoplastic elastomer, a styrene-based thermoplastic elastomer, a urethane-based thermoplastic elastomer, and a polyester-based thermoplastic elastomer. The thermoplastic elastomer may be contained with a content of 5-20 wt.% In at least one of the first and second resins.

At least one first conductive material may comprise at least one kind of conductive material that is not contained in the at least one second conductive material. Under these conditions, at least one first conductive material and at least one second conductive material each may contain at least one of carbon black, graphite, carbon nanotubes, carbon fibers, conductive ceramic fibers, conductive whiskers, metal fibers, conductive inorganic oxides and conductive polymer fibers. In addition, at least one of the first and second conductive materials is made in the form of flakes.

One of the at least one first conductive material and at least one second conductive material may be contained in a first or second PTC formulation with a content of 30-90 wt.%, Preferably 40-80 wt.% Or optimally 60-70 wt. % The other one of at least one first conductive material and at least one second conductive material may be contained in a first or second PTC composition with a content of 20-80 wt.%, Preferably 30-70 wt.% Or optimally 30-60 weight .%.

A PTC resistor according to the present invention may have an electrical resistivity in the range between 0.0007 ohm · m and 0.016 ohm · m, or preferably between 0.0011 ohm · m and 0.0078 ohm · m.

In addition, the PTC resistor of the present invention can exhibit an electrical resistivity at 50 ° C, which is at least two times higher than its electrical resistivity measured at 20 ° C. At a temperature lower than 50 ° C, a PTC resistor according to the present invention may exhibit an electrical resistivity lower than the electrical resistivity of the first or second composition with PTC, along with demonstrating an electrical resistivity higher than 50 ° C greater than those in the first and second composition with PTC.

A PTC resistor according to the present invention can be extended by no more than 5% at a load of less than 7 kgf.

A PTC resistor according to the present invention may have a thermal expansion coefficient between 20 · 10 ^-5 / K and 40 · 10 ^-5 / K.

At least one of the first and second PTC formulations may contain a flame retardant additive. The flame retardant additive may contain at least one phosphorus-based flame retardant, nitrogen-based flame retardant, silicon-based flame retardant, inorganic flame retardant and halogen-based flame retardant. Due to the inclusion of a flame retardant in the additive, the PTC resistor of the present invention satisfies at least one of the following conditions:

(a) when the end of the PTC resistor is fired by a gas flame and the gas flame is extinguished after 60 s, the PTC resistor does not ignite, even if the PTC resistor is charred;

(b) when the end of the PTC resistor is fired by a gas flame, the PTC resistor lights up for no more than 60 s, but the flame is extinguished within 5.08 cm; or

(c) when the end of the PTC resistor is fired by a gas flame, even if the PTC resistor lights up, the flame does not advance at a speed of 10.16 cm / min or greater in a section 1.27 cm thick from the surface.

The flame retardant additive may be contained in a PTC resistor with a content of 5 wt.%, Preferably 0-30 wt.% Or optimally 15-25 wt.%.

A PTC resistor according to the present invention may comprise a liquid resistant resin. The liquid-resistant resin contains at least one of ethylene / vinyl alcohol copolymer, thermoplastic polyester resin, polyamide resin, polypropylene resin and ionomer. The liquid-resistant resin is contained with a content of 10 wt.% Or more, as for the first and second compositions with PTC, preferably 10-70 wt.% Or optimally 30-50 wt.%. As explained above, one of the first resin and the second resin may comprise a reactant resin and a reactive resin that crosslinkes with the reactant resin. The reactive resin may contain a liquid-resistant resin.

Since the sheet heating element of the present invention is formed from a flexible and stable polymer resistor having a high PTC characteristic, it is able to demonstrate excellent performance as a heating element, as well as excellent long life and reliability, and due to the high level of flexibility and manufacturability, labor productivity can be increased and it is possible to produce a polymer resistor with low cost.

BRIEF DESCRIPTION OF THE accompanying drawings

FIG. 1A is a transparent top view of a prior art sheet heating element.

FIG. 1B is a sectional view of the sheet heating element shown in FIG. 1A.

FIG. 2 is an abbreviated cross-sectional view of an example of a design of a prior art sheet heating element manufacturing apparatus.

FIG. 3 is a sectional view of another prior art sheet heating element.

FIG. 4A is a drawing showing a mechanism for exhibiting a PTC characteristic when a prior art particulate conductor is used.

FIG. 4B is a drawing showing a state where the temperature rises from the state shown in FIG. 4A.

FIG. 5 is a graph showing the relationship between the resistivity value of the polymer resistor 5 and the ratio of the resistivity values of the polymer resistor at 50 ° C and 20 ° C (R50 / R20).

FIG. 6A is a graph showing the composition of the polymer resistor 60 of the sheet heating element 1 according to the present invention and a mechanism for developing a PTC characteristic.

FIG. 6B is a drawing showing a state where the temperature rises from the state shown in FIG. 6A.

FIG. 7 is a graph showing the relationship between the resistivity of the polymer resistor 60 and the ratio of the resistivity of the polymer resistor at 50 ° C and 20 ° C (R50 / R20).

FIG. 8 is a graph showing the relationship between the average coefficient of thermal expansion by 1 ° C in the temperature range of -20 ° C and 80 ° C and the coefficient of change of resistivity.

FIG. 9 is a graph showing the relationship between the time that the polymer resistor reaches a predetermined temperature after electric power is applied to it and the coefficient of change of resistivity.

FIG. 10A is a plan view of a sheet heating element of Embodiment 1 of the present invention.

FIG. 10B is a sectional view of the sheet heating element of FIG. 10A.

FIG. 11A is a transparent side view of a car seat to which a sheet heating element of Embodiment 1 of the present invention is attached.

FIG. 11B is a transparent top view of the seat of FIG. 11A.

FIG. 12A is a plan view of a sheet heating element of Embodiment 2 of the present invention.

FIG. 12B is a sectional view of the sheet heating element shown in FIG. 12A.

FIG. 13A is a plan view of a sheet heating element of Embodiment 3 of the present invention.

FIG. 13B is a cross-sectional view of the sheet heating element shown in FIG. 13A.

FIG. 14A is a plan view of a sheet heating element of Embodiment 4 of the present invention.

FIG. 14B is a cross-sectional view of the sheet heating element shown in FIG. 14A.

FIG. 15A is a plan view of a sheet heating element of Embodiment 5 of the present invention.

FIG. 15B is a sectional view of the sheet heating element shown in FIG. 15A.

FIG. 16A is a plan view of a sheet heating element of Embodiment 6 of the present invention.

FIG. 16B is a cross-sectional view of the sheet heating element shown in FIG. 16A.

FIG. 17A is a plan view of a sheet heating element of Embodiment 7 of the present invention.

FIG. 17B is a sectional view of the sheet heating element shown in FIG. 17A.

FIG. 18A is a plan view of a sheet heating element of Embodiment 8 of the present invention.

FIG. 18B is a cross-sectional view of the sheet heating element shown in FIG. 18A.

FIG. 19A is a plan view of a sheet heating element of Embodiment 9 of the present invention.

FIG. 19B is a cross-sectional view of the sheet heating element shown in FIG. 19A.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Embodiments of the present invention are described below with reference to the drawings. It should be noted that the present invention is not limited to these embodiments. Moreover, specific designs for various embodiments can be combined appropriately.

FIG. 6A and FIG. 6B are drawings showing a polymer resistor 60 used in a sheet heating element of the present invention. FIG. 6A shows the internal structure of the polymer resistor 60 at room temperature, and FIG. 6B shows the internal structure of the polymer resistor 60 when the temperature has increased. As described below, the polymer resistor 60 of the present invention can be used as a heat source for a car seat heater. In this case, the polymer resistor 60 is formed in a film configuration and emits heat when electricity is supplied through a pair of linear electrodes 61.

The polymer resistor 60 comprises a resistor composition 62, and the resistor composition 62 is formed from a resin and conductor composition 63. Further, the polymer resistor 60 comprises a resistor composition 65 and the resistor composition 65 is formed from a resin and conductor composition 66. How shown in FIG. 6A, the structure is such that a plurality of clusters of resistor composition 62 are distributed within the polymer resistor 60, and resistor composition 65 surrounds the clusters.

The above characteristic can be achieved if the polymer resistor 60 contains a resistor composition 62 with a content of 20-80 wt.% (The remaining part is the resistor composition 65), preferably 30-70 wt.% (The remaining part is the resistor composition 65) and, in particular, optimally 40-60 wt.% (the remaining part is the resistor composition 65). As the content of the resistor composition 62 approaches the optimal range, the manufacturability and performance of the PTC polymer resistor 60 increases.

The resin composition 63 is formed mainly from a reagent resin in order to achieve a PTC characteristic. A heat dissipation temperature of 40-50 ° C required for a car seat heater is a relatively low temperature. Therefore, a low melting point modified olefin resin such as ethylene / vinyl acetate copolymer, ethylene / ethyl acrylate copolymer, ethylene / methacrylic acid copolymer, ethylene / butyl acrylate copolymer or other ethylene type copolymer can be used as a reagent resin.

Moreover, when the reagent resin reacts with the reactive resin, an internal crosslinked structure is formed. Modified polyethylene containing a carboxyl group is effective as a reagent resin exhibiting PTC characteristics, and modified polyethylene containing epoxy groups can be used as a reactive resin that reacts with it. When such are mixed by kneading, the carbonyl groups in the reactant resin react with the oxygen of the epoxy groups in the reactive resin, chemically bonding and forming a crosslinked structure.

The above characteristic can be achieved if the resin composition 63 contains a reactive resin with a content of 1-20 wt.% (The remaining part is a reagent resin), preferably 1-10 wt.% (The remaining part is a reagent resin) and, in particular , optimally 2-5 wt.% (the remaining part is the reagent resin). As the reactive resin content approaches the optimum range, the processability and performance of the PTC polymer resistor 60 increases.

This crosslinking reaction can occur through nitrogen in addition to oxygen. A crosslinking reaction occurs if a chemically active resin containing a functional group containing at least oxygen or nitrogen, and a reagent resin having a functional group capable of reacting with the functional group of the reactive resin are mixed by kneading. Examples of reactive resin functional groups and reagent resin functional groups other than the above epoxy groups and carbonyl groups are given below.

Examples of functional groups of the reactant resin other than carbonyl groups include epoxy groups, carboxyl groups, ester groups, hydroxyl groups, amine groups, vinyl groups, maleic anhydride groups and oxazoline groups in the polyaddition. Examples of functional groups of a chemically active resin, other than epoxy groups, include oxazoline groups and maleic anhydride groups.

Since the reagent resin has a crosslinked structure due to the reaction with the chemically active resin 63 based on the resin of the resistor composition 62, the temperature characteristics of the thermal expansion coefficient and the melting temperature characteristics of the resistor composition 62 are more stable due to this crosslinking reaction than in the case where the composition 63 based on resin formed exclusively by reagent resin.

Since the reactive resin and the reactant resin strongly bond due to the crosslinked structure even during repeated cooling and heating, resulting in repeated thermal expansion and thermal contraction, the temperature characteristics of the thermal expansion coefficient and the melting temperature characteristics of the resistor composition 62 are preserved, so that their change over time is suppressed . In other words, even as time passes, the resistor composition 62 maintains constant temperature characteristics of the coefficient of thermal expansion and constant characteristics of the melting temperature.

It is not necessary to prepare the resin composition 63 by mixing the reactant resin and the reactive resin by kneading. The PTC characterization may occur even if the reagent resin is used on its own. Therefore, if a change over time in the PTC characteristic is acceptable to some extent, the reagent resin can be used on its own. When the reagent resin is used alone, the type of reagent resin will be selected appropriately according to the desired PTC characteristic value.

In the above description, the reactive resin and the reactant resin are reacted in order to impart a crosslinked structure to the resin-based reactant resin of composition 63. However, a crosslinking agent that is different from a reactive resin can be used. Moreover, it is also possible to form a crosslinked structure in the reactant resin without using a reactive resin, but instead by irradiating the reactant resin with an electron beam. In this case, a reagent resin which does not contain the aforementioned functional groups can be used.

The resin composition 66 of the resistor composition 65 is preferably a resin containing at least one component selected from carboxyl groups, carbonyl groups, hydroxyl groups, ester groups, vinyl groups, amine groups, epoxy groups, oxazoline groups and maleic anhydride groups. These functional groups are the same functional groups as the reagent resin and the chemically active resin of the resin composition 63. Accordingly, the resin composition 66 has a similar chemical nature as the resin composition 63, and the affinity of two of them increases. By using a resin composition 66, which has a high affinity for the resin composition 63, the adhesion (bonding strength) of the resistor resin 62 and the resistor resin 65 increases. At the same time, resin composition 66 can be uniformly dispersed within the polymer resistor.

The resin composition 63 becomes harder due to the crosslinking reaction. Since the resin composition 66 does not have a crosslinked structure, it is flexible and does not harden like the resin composition 63. Due to the fact that this flexible resin composition 66 covers the rigid resin composition 63, the polymer resistor 60 becomes flexible. Accordingly, the polymer resistor 60 can be formed into a film by using a simple machining known as extrusion molding, making it possible to increase productivity in the manufacture of a sheet heating element and reduce costs.

As described below in an embodiment of the present invention, electricity is supplied to the sheet heating element using a pair of linear electrodes 61 separated by a space. In order to supply sufficient exothermic current through such separated electrodes, it is necessary to reduce the resistivity of the polymer resistor 60. An impromptu method for reducing the resistivity is to increase the amount of the conductor 64 of the resin composition 63. However, when the amount of conductor 64 is increased, the resin composition 63 is likely to become solid. In the present invention, the flexibility of the polymer resistor 60 can be maintained while decreasing its resistivity by adding a flexible resin composition 66 to the polymer resistor 60.

Moreover, the resin composition can be made more flexible by adding a thermoplastic elastomer to at least the resin composition 63 and / or the resin composition 66. At least one variety selected from an olefin-based thermoplastic elastomer, a styrene-based thermoplastic elastomer, a urethane-based thermoplastic elastomer, and a polyester-based thermoplastic elastomer can be used as a thermoplastic elastomer.

The amount of thermoplastic elastomer added to the resin composition 63 and the resin composition 66 is preferably in the range of 5-20 wt.% (The remainder is the resin composition 63 or the resin composition 66). When the content of the thermoplastic elastomer is within this range, the flexibility of the polymer resistor 60 is especially enhanced.

The following is an explanation of conductor 64 in resistor composition 62 and conductor 67 in resistor composition 65. In the present invention, conductor 64 and conductor 67 are different types of conductors. Although a single type of conductor can be used respectively as conductor 64 and conductor 67, mixtures of two or more types of conductors can respectively be used. In this case, it is preferable that at least one type of conductor forming the conductor 64 is not contained in the conductor 67.

Conductor 64 is preferably carbon black, and conductor 67 is preferably flake graphite. In addition to those, at least one variety selected from carbon black, graphite, carbon nanotubes, carbon fibers, conductive ceramic fibers, conductive whiskers, metal fibers, conductive inorganic oxides, and conductive polymer fibers can be used as conductor 64 and conductor 67 respectively.

Tinned and activated antimony titanium oxide is an example of a conductive ceramic fiber. The tinned potassium titanate-based compound is an example of a conductive whisker. Aluminum is an example of a metal fiber. Polyaniline is an example of a conductive polymer fiber. Metal-coated mica is an example of a conductive inorganic oxide.

The conductors used in conductor 64 and conductor 67 are selected appropriately according to the desired PTC characteristic. The resistivity of the polymer resistor 60 is appropriately selected according to the use of the polymer resistor 60. For example, if it should be thin and elongated for use in a car seat heater, the resistivity of the polymer resistor depends on the distance between the linear electrodes and is preferably in the range of about 0, 0007 Ohm / m to about 0.016 Ohm / m, and is optimally in the range of about 0.0011 Ohm / m to about 0.0078 Ohm / m.

Moreover, at least one type of metal powder and conductive non-metal powder can also be added to the resistor composition 65, thereby making it possible to lower the resistivity of the polymer resistor 60.

As shown in FIG. 6A, when the sheet heating element is not in a place where it radiates heat, the conductors 64 in the resistor composition 62 are close to each other and touch each other at points in the resin composition 63, thereby forming conductive paths. On the other hand, the conductors 67 in the resistor composition 65 are also close to each other, thereby forming conductive paths.

When a current is applied to the electrodes 61, current flows through the conductive paths of the conductor 64 and the conductive paths of the conductor 67, and the polymer resistor 60 is heated. When the polymer resistor 60 is heated, the resin composition 63 and the resin composition 66 undergo thermal expansion. As shown in FIG. 6B, along with the thermal expansion of the resins, the conductors 64 are removed from each other, and the conductors 66 are also removed from each other. As a result, the conductive paths break off and the resistance of the polymer resistor 60 increases. In other words, as the temperature rises, a PTC characteristic appears in which the resistance of the polymer resistor 60 increases.

Due to the fact that graphite or a conductive inorganic oxide are in the form of flakes, the contact surface areas between the conductors increase. In other words, the electrical resistance of the polymer resistor 60 decreases at low temperatures. As a result, as the temperature rises, the resistance of the polymer resistor 60 rises significantly. In other words, the polymer resistor 60 exhibits an excellent PTC characteristic that has highly positive temperature resistance characteristics.

As described above, the reagent resin, which is the basic composition of the resin composition 63 of the resistor composition 62, is induced to form a crosslinked structure by reacting the reagent resin with a reactive resin. Due to this crosslinked structure, the resin conductor 64 of 63 is stably located, and the conductive paths are stably formed at low temperatures. On the other hand, when the temperature rises, it will always be constant, at which the conductive paths break. In other words, the crosslinked structure allows the polymer resistor 60 to constantly exhibit a stable PTC characteristic.

The above characteristic can be achieved if the resistor composition 62 contains a conductor 64 with a content of 30-90 wt.% (The remaining part is a resin composition 63), preferably 40-80 wt.% (The remaining part is a resin composition 63) and in particular, optimally 60-70 wt.% (the remaining part is a resin-based composition 63). On the other hand, the above characteristic can be achieved if the resistor composition 65 contains a conductor 67 with a content of 20-80 wt.% (The remaining part is a resin composition 66), preferably 30-70 wt.% (The remaining part is a 66 based on the resin) and, in particular, optimally 30-60 wt.% (the remaining part is a composition 66 based on the resin). As the content of the conductor 64 and the conductor 67 approaches the optimal range, the manufacturability and characteristic of the PTC polymer resistor 60 is enhanced.

FIG. 7 is a graph showing the relationship between the resistivity of the polymer resistor 60 at 20 ° C and the coefficient of change of resistance, which is the ratio of the resistivity of the polymer resistor at 50 ° C and 20 ° C (R50 / R20). The higher the coefficient (R50 / R20) of the change in resistivity, the greater the change in resistance at low and high temperatures. In other words, the higher the coefficient (R50 / R20) of the change in resistivity, the better the PTC characteristic.

Tests were conducted in which the types of composition 63 based on resin, conductor 64, composition 66 on the basis of resin and conductor 67 were varied differently, and the resistivity values were measured for each at 50 ° C and at 20 ° C to obtain the coefficients of change in resistivity (R50 / R20). Moreover, the proportions of the composition of these components varied and similar tests were carried out. FIG. 7 shows plots of the coefficient (R50 / R20) of the change in resistivity in each of these cases.

The test results are shown in FIG. 7, where the polymer resistors 60 used in the tests are divided into two groups. In the case of the polymer resistor 60 shown as Group 1, the tests were carried out after changing the type of components and their proportions, but the same material was always used as the conductor 64 and conductor 67. In the case of the polymer resistor 60 shown as Group 2 , tests were carried out in a similar way, after changing the type of components and their proportions, but different materials were always used as conductor 64 and conductor 67.

As shown in FIG. 7, in the case of Group 1 (the same material was used as conductor 64 and conductor 67), the resistivity at 20 ° C was in the range from 0.05 Ohm / m to 12 Ohm / m, and the total coefficient (R50 / R20) changes resistivity was 2 or lower. In the case of Group 2 (different materials were used as conductor 64 and conductor 67), the resistivity at 20 ° C was in the range from 0.08 Ohm / m to 4 Ohm / m, and the total coefficient (R50 / R20) of the change in resistivity was 2 or higher.

The changes in resistivity accompanying temperature rises were measured for polymer resistor 60 with a coefficient (R50 / R20) of change in resistivity of 2 or higher. Moreover, changes in the resistivity value accompanying temperature rises were measured similarly for each resistor composition 62 and resistor composition 65, which form the polymer resistor 60. When the results of these measurements were compared, the resistivity of the polymer resistor 60 at a temperature of less than 50 ° C were found smaller than the resistivity of the resistor composition 62 and the resistivity of the resistor composition 65 at the same temperature.

As the temperature rises to approach 50 ° C, the resistivity of the polymer resistor 60 approaches the resistivity of the resistor 62 and the resistivity of the resistor 65. When the temperature exceeds 50 ° C, the resistivity of the polymer resistor 60 becomes greater than the values of the resistivity of the resistor composition 62 and the resistor composition 65.

In other words, it was found that when the resistor composition 62 and the resistor composition 65 are mixed, a higher temperature characteristic is demonstrated than the temperature characteristic shown by each of them individually. It was also found that when the resistor composition 62 and the resistor composition 65 are mixed, the resistivity at low temperature is lower than the values of the resistivity of each of them individually, and the resistivity at high temperatures is higher than the values of the resistivity of each of them individually . This characteristic is noteworthy, especially when carbon black is used as conductor 64 and when graphite is used as conductor 67.

The reason why this phenomenon occurs is not understood, but it is believed that due to the fact that the types of conductors are different, the shape and size of the particles, the density of the conductive paths in the resistor compositions 62 and 65, and the electrical conductivity between the resin compositions 63 and 66 influence each other friend. In addition, the difference in thermal expansion and the difference in melting temperature between resin compositions 63 and 66 play an important role.

Then 3 types of resin-based compositions with different melting points were used to make polymer resistor 60 in 3 types of films. The type and quantity of conductor in these 3 types of resin compositions were identical. However, the resistivity coefficients (R50 / R20) for these 3 types of resin compositions were approximately 1.4, approximately 2.0, and approximately 2.9, respectively. The melting points of these resin-based formulations were about 40 ° C for a polymer resistor film with a coefficient of change in resistivity of approximately 1.4; about 60 ° C for a film of a polymer resistor with a coefficient of change in resistivity of approximately 2.0; and about 80 ° C for a polymer resistor film with a coefficient of change in resistivity of approximately 2.9. The thermal expansion of these 3 types of polymer resistor films in planar orientation was tested using a TMA-50 thermal analysis device (Shimadzu Corporation). The results are shown in FIG. 8.

In detail, with a temperature change of 1 ° C at a time in the temperature range from -20 ° C to 80 ° C, the thermal expansion coefficient was measured for each of the 3 types of polymer resistors at each increment, and in conclusion, the thermal expansion coefficients were averaged. FIG. 8 shows the relationship between the average coefficient of thermal expansion and the coefficient of change of resistivity for the three resistors. FIG. 8 clearly shows that the lower the coefficient of change in resistivity, the lower the coefficient of thermal expansion, and the greater the coefficient of change in resistivity, the greater the coefficient of thermal expansion. In other words, polymer resistors using resin compositions with lower melting points exhibit higher resistivity changes. These tests show that polymer resistors using low melting point resin compositions have high thermal expansion coefficients in the low temperature ranges.

FIG. 8 combines the 3 resulting average thermal expansion coefficients into a curve. This curve shows that the average coefficient of thermal expansion for polymer resistors, for which the coefficient of change in resistivity is 2, is approximately equal to 20 · 10 ^-5 / K. Based on this discovery, it can be predicted that the average coefficient of thermal expansion for polymer resistors, for which the coefficient of change in resistivity is 2 or more, is approximately equal to 20 · 10 ^-5 / K or more. In other words, it is believed that polymer resistors with an average coefficient of thermal expansion of 20 · 10 ^-5 / K or more should exhibit a favorable PTC characteristic.

The thermal expansion coefficient of the resin-based composition typically reaches a maximum near its melting point and gradually decreases when this point is exceeded. If the resin composition melts after the melting point, the concept of thermal expansion coefficient for solids is no longer applied. Therefore, if the maximum coefficient of thermal expansion near the melting point is used as the upper limit, the range of thermal expansion coefficients of polymer resistors exhibiting suitable PTC characteristics is from 20 · 10 ^-5 / K to 40 · 10 ^-5 / K.

If the coefficient of thermal expansion of the polymer resistor is greater than the coefficient of thermal expansion of the substrate to which the polymer resistor is attached, it is likely that wrinkles could form in the polymer resistor when it is heated, and the durability could be lost. Therefore, when choosing a polymer resistor with a coefficient of thermal expansion in the above range, it is necessary to take into account the coefficient of thermal expansion of the substrate to which the polymer resistor is attached.

FIG. 9 shows the relationship between the time and the coefficient of change of the resistivity when electrical power was supplied to 3 types of polymer resistors, and the time was measured until the polymer resistor reached temperatures of 25 ° C and 30 ° C. The temperature, when the electric power started to be applied, was -20 ° C, and the hypothetical use was in the car seat heater, and the polymer resistor was squeezed to simulate the state in which the passenger was seated. When electrical power began to be applied, it was set to be constant when the temperature reached approximately 40 ° C. In other words, the lower the coefficient of change in resistivity, the lower the electrical power during initial use.

FIG. 9 shows that polymer resistors with high resistivity coefficients exhibit a faster temperature increase. FIG. 9 combines the resulting 3 points on the curve for temperatures of 25 ° C and 30 ° C, respectively. The curve shows that polymer resistors with a coefficient of change of resistivity of 2 require about 2 minutes to reach 25 ° C, and about 5 minutes to reach 30 ° C. When the sheet heating element 60 is used in a car seat heater, it is preferable that the sheet heating element generates heat so that the time to reach 20 ° C is within 2 minutes and the time to reach 30 ° C is within 5 minutes. As shown in FIG. 9, it was confirmed that a coefficient of change in the resistivity of the polymer resistor is required, which must be 2 or more in order to satisfy an empirical condition.

If the polymer resistor 60 is used in a car seat heater, it is even more useful that the polymer resistor 60 contains a flame retardant. The car seat heater must meet the US Flammability Standard, FMVSS 302. More precisely, it must satisfy any one of the conditions below.

(1) When the end of the polymer resistor 60 is fired by a gas flame and the gas flame is extinguished after 60 seconds, the polymer resistor 60 does not ignite, even if the polymer resistor 60 is carbonized.

(2) When the end of the polymer resistor 60 is fired by a gas flame, the polymer resistor 60 lights up for no more than 60 s, but the flame is extinguished within 5.08 cm.

(3) When the end of the polymer resistor 60 is fired by a gas flame, even if the polymer resistor 60 is ignited, the flame does not advance at a speed of 10.16 cm / min or more in a section 1.27 cm thick from the surface.

Flammability is determined as follows. The end of the sample is fired for 60 with a gas flame. When the flame is extinguished after 60 s, the sample does not burn, even if the charred residue remains on the sample. Self-extinguishing refers to a sample igniting for no more than 60 s, and the burnt area is within 5.08 cm.

More precisely, the flammability standards can be satisfied by adding a flame retardant to resistor 62 and / or resistor 65, which form a polymer resistor 60. The flame retardant can be a phosphorus based flame retardant, such as ammonium phosphate or nitrogen based tricresyl phosphate. a compound such as melamine, guanidine, guanyl urea; or silicon based compound; or a combination of those. An inorganic flame retardant, such as magnesium oxide or antimony anhydride, or a halogen-based flame retardant, such as a bromine-based or chlorine-based compound, can be used.

It is especially advantageous if the flame retardant additive is a liquid at room temperature or has a melting point, so that it melts at a mixing temperature. The flexibility of the resistor composition 62 and the resistor composition 65 can be increased by using at least one type of phosphorus based, ammonium based or silicon based compound, thereby making it possible to increase the flexibility of the polymer resistor 60 as a whole.

The amount of flame retardant additive to be added is determined as follows. If there is a small amount of flame retardant, the incombustibility becomes insufficient, and any of the above conditions for incombustibility is not satisfied. In view of this, the amount of flame retardant additive to be added must be 5% by weight or more with respect to the polymer resistor 60. However, when the amount of flame retardant additive increases, the compositional balance between the resin compositions 63, 66 and the conductors 64, 61, contained therein becomes insufficient, the resistivity of the polymer resistor 60 increases, and the PTC characteristic becomes insufficient. In view of this, the amount of the flame retardant additive to be added is preferably 10-30 wt.%, And optimally 15-25 wt.% With respect to the polymer resistor 60.

The flame retardant additive can be added after mixing the resistor composition 62 and the resistor composition 65. It can be added in advance to at least the resin composition 63 forming the resistor composition 62 and / or the resin composition 66 forming the resistor composition 65. Properties of the flame retardant composition can be achieved by the presence of flame retardant additives in the polymer resistor 60.

It is useful to add a liquid-resistant resin to the polymer resistor 60 so as to impart the liquid resistance to the polymer resistor 60. The liquid resistance prevents the polymer resistor 60 from being damaged due to contact with liquid chemicals such as inorganic oils, including motor oil, polar oils, such like brake oil, and other oils, low molecular weight solvents, such as diluents and other organic solvents.

When the polymer resistor 60 comes into contact with the above liquid chemicals, the resin composition 63 and the resin composition 66, which contain large amounts of amorphous resin, expand rapidly and the volume increases, so that the conductive paths of the conductors are broken and the resistance increases. This phenomenon is identical to volume changes (or PTC characteristics) due to heating. When the polymer resistor 60 comes into contact with the liquid chemical described above, the initial resistivity value is not restored even if the liquid dries. Even if it is restored, recovery takes time.

In order to impart liquid resistance to the polymer resistor 60, a highly crystallized liquid-resistant resin is added to the polymer resistor 60, so that the resin composition 63, the resin composition 66, the conductor 64, and the conductor 67 are partially chemically bonded to the liquid-resistant resin. As a result, even if the polymer resistor 60 comes into contact with the liquid chemical described above, the expansion of the resin composition 63 and the resin composition 66 slows down.

The liquid-resistant resin contains one component selected from ethylene / vinyl alcohol copolymer, thermoplastic polyester resin, polyamide resin, polypropylene resin and ionomer, or may contain a combination thereof. These fluid-resistant resins not only impart fluid resistance to the polymer resistor 60, but they also act to prevent a decrease in the flexibility of the resin composition 63 and the resin composition 66. In other words, these liquid-resistant resins support the flexibility of the polymer resistor 60.

The amount of liquid-resistant resin added is preferably 10% by weight or more with respect to the resin composition 63 and the resin composition 66 in the polymer resistor 60. Thus, the liquid resistance of the polymer resistor 60 is increased. However, when there is a large amount of liquid-resistant resin, the polymer resistor 60 itself will become solid and its flexibility will decrease. In addition, the conductors will be absorbed within the fluid-resistant resin, and the conductive paths will hardly break even when the temperature rises, and the PTC characteristic will eventually drop. Therefore, in order to maintain the flexibility of the polymer resistor and to maintain a favorable PTC characteristic, the amount of liquid-resistant resin is preferably in the range of 10-70 wt.%, And optimally 30-50 wt.%.

The following test was conducted to study the effects of the liquid-resistant resins described above. First of all, a plurality of polymer resistors 60 were prepared without a liquid-resistant resin, and a plurality of polymer resistors 60 were prepared containing correspondingly different liquid-resistant resins (50 wt.%). The aforementioned liquid chemical dripped onto these polymer resistors 60 and were allowed to remain for 24 hours. After applying electric current to these polymer resistors 60 for 24 hours, they were allowed to remain at room temperature for 24 hours. The resistivity values of these polymer resistors were measured before and after the test. It was found that polymer resistors 60, which do not contain a liquid-resistant resin, showed a 200-300-fold increase in resistivity compared to the previous test.

In contrast, in all polymer resistors 60, which contained liquid-resistant resins, the increase in resistivity was small than 1.5-3 times compared with the previous test. This test showed that the addition of a liquid-resistant resin to the polymer resistor 60 makes it possible to inhibit the expansion of the resin composition 63 and the resin composition 66 forming the polymer resistor 60, which may be caused by contact with a liquid chemical such as organic solvents or drinks. In other words, the resistivity of the polymer resistor 60 can be stabilized, the sheet heating element can have a high level of durability by adding a liquid-resistant resin to the polymer resistor 60.

The above liquid-resistant resin can be added after mixing the resistor composition 62 and the resistor composition 65. However, the liquid-resistant resin is added to increase the liquid resistance of the composition 63 based on the resin forming the resistor composition 62, or the composition 66 based on the resin forming the resistor composition 65 therefore, it is useful to add to at least the resin composition 63 and / or the resin composition 66 in advance. However, no matter what method is used, the polymer resistor 60 is able to exhibit liquid resistance, since ultimately a liquid-resistant resin is present in the polymer resistor 60.

In the above polymer resistor 660 according to the present invention, there are two varieties of resistor compositions 62 and 65, which respectively comprise resin compositions 63 and 66. An object of the present invention can also be achieved by forming a polymer resistor with a single resin-based resistor composition containing a single resin-based composition.

A single resin composition contains a low melting point modified olefin resin such as ethylene / vinyl acetate copolymer, ethylene / ethyl acrylate copolymer, ethylene / methyl methacrylate copolymer, ethylene / methacrylic acid copolymer, ethylene / butyl acrylate copolymer or other ethylene type copolymer. The resin composition may also contain a reactive resin, such as described above, to provide a crosslinking structure to the resin resistor composition. The functional groups described above provide the resin composition and the chemical resin with the ability to crosslink together. In the absence of a reactive resin, a crosslinking structure can be imparted to the resin-based resistor composition by irradiating the resin-based composition with an electron beam.

A single resin-based composition can be made flexible by adding at least one of the above thermoplastic elastomers with the content described above.

A single resin-based resistor composition contains at least two kinds of conductors selected from the above conductors with the contents described above. The conductors used in the resin-based resistor composition are selected appropriately according to the desired PTC characteristic.

The resistivity of the polymer resistor is appropriately selected according to the use case of the polymer resistor. For example, if it is to be thin and elongated for use in a car seat heater, the resistivity of the polymer resistor depends on the distance between the line electrodes and is preferably in the range of from about 0.0007 ohm / m to about 0.016 ohm / m, and is optimally in a range from about 0.0011 ohm / m to about 0.0078 ohm / m.

Option 1 implementation of sheet heating element

The following is a description of an embodiment of a sheet heating element using the above-described polymer resistor. FIG. 10A is a plan view of Embodiment 1 of a sheet heating element of the present invention, and FIG. 10B is a sectional view of the sheet heating element of FIG. 10A, along line 10B-10B.

The sheet heating element 100 includes an insulating substrate 101, a first linear electrode 61A, a second linear electrode 61B, and a polymer resistor 60. The linear electrodes 61A, 61B are sometimes collectively referred to as linear electrodes 61. The linear electrodes 61A, 61B are symmetrically left and right on the insulating substrate 101 and partially sewn to the insulating substrate 101 by a thread 102. Using an extruder extruding the film through a flat slot mouthpiece, for example a polymer resistor 60, can be obtained by extrusion as lenoks on the insulating substrate 101, to which were attached the linear electrodes 61 and laminator thermally glued together in order to create electrical contact with the linear electrodes 61.

After the polymer resistor 60 is extruded onto the linear electrodes 61 and the insulating substrate 101, the central part of the sheet heating element breaks through. The position where the central part is pierced is not limited to the position shown in the drawing. There are cases in which the punching of the central part is in other positions, depending on the application. In order to avoid punching, the wiring pattern of the linear electrodes 61 must be modified.

The above-described sheet heating element 100, for example, is used in a car seat heater. In this case, as shown in FIG. 11A and 11B, the sheet heating element 100 is attached to the seat portion 111 and to the rear back 112, which in some way rises from the seat portion 111. The heating element 100 is attached so that the insulating substrate 101 is located on the side of the surface of the seat. The seat portion 111 and the rear back 112 have a seat base material 113 and a seat cover 114 covering the seat base material 113. The seat base material 113 is formed from a flexible material, such as a urethane cushion, and changes shape when the load is applied by a sitting person, and restores its original shape when the load is removed. The sheet heating element 100 is connected to the side of the polymer resistor 60 facing the seat base material 113 and to the insulating substrate 101 facing the seat cover 114.

Since the sheet heating element 100 has a PTC characteristic, a small amount of energy is consumed as the temperature rises rapidly. A heating element without a PTC characteristic must additionally have a thermostat. This additional temperature regulator regulates the temperature of heat generation, turning the current on and off. In particular, when the heating element has linear heat rays, there are several low-temperature spaces between the linear heat rays. In order to reduce these low temperature spots as much as possible, in the case of a heating element without a PTC characteristic, the heat dissipation temperature rises to approximately 80 ° C when turned on. Thus, a heating element without a PTC characteristic should be located within the seat at some distance from the seat cover 114.

In contrast, in the case of a sheet heating element 100 that has a PTC characteristic, the heat dissipation temperature is automatically controlled so as to be in the range of 40 ° C to 45 ° C. Since the heat dissipation temperature is kept low in such a sheet heating element 100, it may be located closer to the seat cover 114. In addition, since the heating element is located near the seat cover 114, it can quickly transfer heat to the seated passenger. Moreover, since the heat dissipation temperature is kept low, energy consumption can be reduced.

The polymer resistor 60 according to the first embodiment of the invention is hereinafter described in more detail. Reagent resin formed from 30 parts of an ethylene / methyl acrylate copolymer (Akurifuto CM5021 product of Sumitomo Chemical, melting point 67 ° C) and 30 parts of an ethylene / methacrylate acid copolymer (Nyukureru N1560 product of Mitsui-Dupont Polychemical, with a melting point of 90 ° C), and a liquid-resistant resin formed from 40 parts of an ion-containing resin (Mitsui-Dupont Polychemical Haimiran 1702 product, with a melting point of 90 ° C) crosslinked by metal ions between the copolymer molecules ethylene / metal acrylate acid (meta focal-crystal compound) are mixed to form resin compound, formed of the resin reactant and a liquid-resistant resin. Since the above liquid-resistant resin contains a functional group of carbonic acid, it also acts as a reactive resin.

35 wt.% Of this resin-based composition, 2 wt.% Of a reactive resin (Sumitomo Chemical’s Bond First 7B product), 25 wt.% Carbon black (Degussa's Printex L product, with a major particle size of 21 nm) and 18 wt.% Graphite (Nihon Kokuen GR15 plate graphite product) as two types of conductors and 20 wt.% Flame retardant additives (based on orthophosphoric esters of the flame retardant composition Reofos RDP) were mixed to make resistor composition 62.

Then, resistor composition 65 was created from 40 wt.% Styrene-based thermoplastic elastomer (Asahi Kasei Engineering's Tafutekku M1943 product) as an elastomer, 45 wt% carbon black (Mitsubishi Chemical's # 10B product, with a main particle size of 75 nm ), and 13% by weight of tungsten carbide (Isawa product) and 2% by weight of a mixture of acryl methacrylate / alkyl acrylate copolymer and ethylene tetrafluoride (Metaburen A3000 product of Mitsubishi Rayon Limited Liability Company).

Then, the resistor compositions 62 and 65 were mixed and mixed with 2 wt.% Of the modified silicone oil as a mold release agent and 2 wt.% Of an acrylic methacrylate / alkyl acrylate copolymer as a flow improver. These were then mixed using a device such as a hot mill, mixer, biaxial mixer, or the like. This mixture was extruded from a flat slot extruder mouthpiece and formed into a film to create a polymer resistor 60.

There is no particular limitation on the thickness of the polymer resistor 60, but when flexibility, material costs, proper resistance and strength are taken into account when a load is applied, a thickness of 20-200 microns, and preferably 30-100 microns, is suitable.

Since the polymer resistor 60 is a flexible film, it stretches and changes its shape in the same way as the insulating substrate 101 when an external force is applied to the sheet heating element 100. The polymer resistor 60 must be as flexible as or more flexible than the insulating substrate 101 If the polymer resistor 60 is as flexible as, or more flexible than, the insulating substrate 101, then the durability and reliability of the polymer resistor 60 is increased since the insulating substrate 101 has a greater fur strength than polymer resistor 60, and when an external force is applied, it is used to limit the stretching or shape change of polymer resistor 60.

It should be noted that the liquid-resistant polymer and the flame retardant additive can be added to the resistor composition 65 and they can be added in appropriate amounts to both the resistor composition 62 and the resistor composition 65.

A pair of linear electrodes 61A, 61B that are facing each other are provided in two rows in the longitudinal direction of the sheet heating element 100. The polymer resistor 60 is configured to overlap a pair of linear electrodes 61A, 61B, respectively. When electricity is supplied from the line electrodes 61A, 61B to the polymer resistor 60, current flows to the polymer resistor 60 and the polymer resistor 60 heats up.

The linear electrodes 61 are sewn by the sewing machine to the insulating substrate 101 with polyester thread 102. Thus, the linear electrodes 61 are firmly attached to the insulating substrate 101, allowing them to change their shape as the insulating substrate 101 changes shape, thereby increasing mechanical reliability sheet heating element.

Linear electrodes 61 are formed of at least a metal conductor wire and / or twisted metal conductor wires, in which the metal conductor wires are twisted together. The wire material of the metal conductor may be copper, tinned copper or a silver-silver alloy. From the point of view of mechanical strength, it is useful to use a copper-silver alloy, since it has a high tensile strength. In detail, the linear electrode 3 is formed by twisting together 19 wires of a copper-silver alloy with a diameter of 0.05 μm.

The resistance of the linear electrodes 61 should be as low as possible, and the voltage drop along the linear electrodes 61 should be small. The resistance of the linear electrode 61 is selected so that the voltage drop at the voltage applied to the sheet heating element is 1 V or less. In other words, it is useful that the resistivity of the linear electrode 61 be 1 Ohm / m or lower. If the diameter of the linear electrodes 61 is large, they form bulges on the sheet heating element 100, resulting in a loss of comfort when sitting on it. Therefore, the diameter should be 1 mm or less, and a diameter of 0.5 mm or less is desirable for an even more comfortable feeling when sitting on it.

The distance between the pair of linear electrodes 61 should be in the range of about 70-150 mm. For practical purposes, the distance between the linear electrodes 61 should be about 100 mm. If the distance between the electrodes is less than about 70 mm when a person sits on the sheet heating element 1 and the buttocks are pressed against the linear electrodes 61, it is likely that the load and bending force will cause the linear electrodes to break or become damaged. On the other hand, if the distance between the electrodes is greater than 150 mm, the resistivity of the polymer resistor 60 should be reduced to a very low level, making it difficult to fabricate a useful polymer resistor 60 that has a PTC characteristic.

If the distance between the electrodes 61 is 70 mm, since the film thickness of the polymer resistor 60 is 20-200 μm, as mentioned above, and preferably 30-100 μm, the resistivity of the polymer resistor 60 should be in the range of about 0.0016-0.016 Ohm / m, and preferably about 0.0023-0.0078 Ohm / m. Furthermore, if the distance between the linear electrodes 61 is 100 mm, the resistivity of the polymer resistor 60 should be in the range of about 0.0011-0.011 Ohm / m, and preferably about 0.0016-0.0055 Ohm / m. Moreover, if the distance between the linear electrodes 61 is 150 mm, the resistivity of the polymer resistor 60 should be in the range of about 0.0007-0.007 Ohm / m, and preferably about 0.0011-0.0036 Ohm / m.

It should be noted that in this embodiment, the linear electrode is used as the electrode, but the present invention is not limited thereto, and it is also possible to use a metal foil electrode or an electrode membrane made by screen printing of silver paste or the like.

Non-woven fabric formed from polyester fibers is punched using needle punching and can be used for insulating substrate 101. A woven fabric formed from polyester fibers can also be used. The insulating substrate 101 imparts flexibility to the sheet heating element 100. The sheet heating element 100 can easily change its shape if an external force is applied. So, if it is used in a car seat heater, the feeling of comfort when sitting on it improves. The sheet heating element has the same elongation properties as the seat cover material. More precisely, under an applied load of 7 kgfs or less, it stretches by a maximum of 5%.

As mentioned above, the linear electrodes 61 are sewn onto the insulating substrate 101. Due to sewing, needle holes are formed in the insulating substrate 101, but the aforementioned non-woven fabric or woven fabric prevents cracks from propagating from the needle holes.

Non-woven or woven fabric made of polyester fibers has good ventilation properties, and when used as a car seat heater or steering wheel heater, moisture will not accumulate. Thus, even when sitting on it or grabbing for a long period of time, the initial comfortable sensation is maintained and is very pleasant. And since no sound like sitting on paper is made when the passenger is seated, the seat does not lose its sense of comfort, even with a sheet heating element 100 located inside.

The sheet heating element of the prior art was formed from a 5-6-layer structure including a substrate, an electrode, a polymer resistor, a hot-melt polymer and a coating material. In contrast, the sheet heating element 100 of the present invention is formed of 3 layers, namely an insulating substrate 101, a pair of linear electrodes 61 and a polymer resistor 60. Since this structure is simple, there are few structural elements that will be affected when an external force is applied. In other words, the sheet heating element 100 is more flexible than the prior art heating element. Therefore, if it is attached to the seat as a car seat heater, it will easily change shape in response to external force, and cracks and peeling of the polymer resistor caused by folds are protected from occurrence.

Option 2 implementation of a sheet heating element

FIG. 12A is a plan view of a sheet heating element 120 of Embodiment 2 of the present invention, and FIG. 12B is a sectional view taken along line 12B-12B of FIG. 12A. The structure is different from that of Embodiment 1 (see FIGS. 10A, 10B) because linear electrodes 121 are arranged in wavy lines on an insulating substrate 101.

As shown in FIG. 12A, the linear electrodes 121 are arranged in wavy lines on the insulating substrate 101, being attached by the filament 102. According to this structure, when an external force is applied to the sheet heating element 120, since the linear electrodes 121 are arranged in wavy lines, having an allowance in terms of length, they are easily change shape in response to tension, stretching and bending. Therefore, the wavy linear electrodes 121 have a mechanical strength with respect to an external force that is better than that of the linear electrodes 61.

In addition, in the areas where the wavy linear electrodes 121 pass, the voltage applied to the polymer resistor 60 becomes uniformly distributed, and the distribution of the heating temperature of the polymer resistor 5 becomes uniform.

Option 3 implementation sheet heating element

FIG. 13A is a plan view of a sheet heating element 130 of Embodiment 3 of the present invention, and FIG. 13B is a sectional view taken along line 13B-13B of FIG. 13A. The structure is different from that of Embodiment 1 (see FIGS. 10A, 10B) because the auxiliary linear electrodes 131 are arranged between a pair of linear electrodes 61. In other words, the auxiliary linear electrodes 131 are arranged between a pair of linear electrodes 61 and sewn onto an insulating the substrate 101 by means of a sewing machine, using a thread 132 made of polyester fibers or the like, as in the case of linear electrodes 61.

In the construction shown in FIG. FIG. 10A, the polymer resistor 60 is predisposed to heat up unevenly between the line electrodes 61, and the resistivity for such a portion increases, focusing there on the electric potential. If this condition continues, the temperature of such a part of the polymer resistor 60 rises more than the other parts, resulting in what is known as the phenomenon of hot lines. By providing auxiliary linear electrodes 131, as in FIG. 13A, the electric potential becomes uniform throughout the entire polymer resistor 60, so that the heating temperature becomes uniform. Therefore, the phenomenon of hot lines can be prevented from occurring in the polymer resistor 60.

It should be noted that, like the linear electrodes 61, the auxiliary linear electrodes 131 are formed of a metal conductor or twisted metal conductors.

In FIG. 13A and FIG. 13B, two auxiliary linear electrodes 131 are arranged between a pair of linear electrodes 61. But the number of auxiliary linear electrodes 131 is not limited to this, and the number can be determined according to the size of the polymer resistor 60, the distance between the linear electrodes 61 and the desired heat distribution.

In FIG. 13A, the auxiliary linear electrodes 131 are arranged almost parallel to the pair of linear electrodes 61. But the arrangement is not limited thereto, and the auxiliary linear electrodes 131 can also be arranged in a zigzag configuration between the pair of linear electrodes 61.

Moreover, the auxiliary linear electrodes 131 can be arranged in a wavy configuration of the linear electrodes 121 of Embodiment 2, as shown in FIG. 12A and 12B. Of course, the wave-like linear electrodes 121 and the wave-like auxiliary linear electrodes 131 can be combined.

Option 4 implementation sheet heating element

FIG. 14A is a plan view of a sheet heating element 140 of Embodiment 4 of the present invention. FIG. 14B is a sectional view taken along line 14B-14B of FIG. 14A. The structure is different from that of Embodiment 1 (see FIGS. 10A, 10B) because the polymer resistor 60 is located by inserting it between the insulating substrate and the linear electrodes 61.

The sheet heating element 140 of Embodiment 4 is manufactured as follows. First, the polymer resistor 60 is hot laminated as a film on the insulating substrate 101. Then, the linear electrodes 61 are assembled on the polymer resistor 60 and sewn onto the insulating substrate 101 by a sewing machine. The linear electrodes 61 and the polymer resistor 60 are thermally compressed so that the linear electrodes 61 are glued to the polymer resistor 60. Since the linear electrodes 61 are located on the polymer resistor 60, the arrangement position of the linear electrodes 61 can be easily checked. When the central portion of the insulating substrate 101 is punched in order to increase flexibility, the piercing of the linear electrodes 61 can be reliably avoided.

In addition, since the linear electrodes 61 are sewn onto the insulating substrate 101 to which the polymer resistor 60 is attached, there is a large degree of freedom in the arrangement of the linear electrodes 61. A variety of different sheet heating elements 140 can be easily manufactured by carrying out a sequence of operations of attaching the polymer resistor 60 to the insulating a substrate 101, of general processing, after which the linear electrodes 61 can be sewn in a variety of arrangements to have a variety of heating profiles.

Moreover, in this embodiment, auxiliary line electrodes 131 shown in FIG. 13A.

In addition, in this embodiment, the linear electrodes 61 and the polymer resistor 60 are thermally bonded. But the present invention is not limited to this. Linear electrodes 61 and polymer resistor 60 can also adhere by means of a conductive binder. The line electrodes 61 and the polymer resistor 60 can also be electrically connected by mechanical contact by simply pressing them together.

Option 5 implementation sheet heating element

FIG. 15A is a plan view of a sheet heating element 150 of Embodiment 5 of the present invention. FIG. 15B is a sectional view taken along line 15B-15B of FIG. 15A. The structure is different from that of Embodiment 4 (see FIGS. 14A, 14B) because conductive strips are provided along which the linear electrodes 61 are sliding between the polymer resistor 60 and the linear electrodes 61.

The sheet heating element 150 of Embodiment 5 is manufactured as described below. The polymer resistor 60 is hot laminated as a film on the insulating substrate 101. After that, the conductive strips 151 are mounted on this polymer resistor 60. Then, the linear electrodes 61 are assembled on the conductive strips 151 and sewn onto the insulating substrate 101 by a sewing machine. The linear electrodes 61 and the polymer resistor 60 are thermocompressed, so that the polymer resistor 60 adheres tightly to the linear electrodes 61.

The conductive strips 151, for example, are formed from films made from dried graphite paste or from films made from a resin-based compound containing graphite. When the conductive strips 151 are mounted on the polymer resistor 60, these films are laminated by hot lamination on the polymer resistor 60 or drawn on it.

Since the linear electrodes 61 are sliding along the conductive strips 151, the flexibility of the sheet heating element 150 is further enhanced. Since the conductive strips 151 have excellent conductivity, the linear electrodes 61 and the polymer resistor 60 are more reliably electrically connected through the conductive strips 151.

It should be noted that in this embodiment, auxiliary linear electrodes 131 described in Embodiment 3 can also be further provided (see FIG. 13A). Moreover, conductive strips 151 may also be provided for auxiliary linear electrodes 131.

In addition, in Embodiment 1 (see FIGS. 10A, 10B), if conductive strips 151 are provided between the line electrodes 61 and the polymer resistor, a similar beneficial result can be expected. In this case, the conductive strips 151 can be positioned in advance at some position on the polymer resistor 60, while facing the linear electrodes 61.

In this embodiment, the conductive strips 151 are mounted on the polymer resistor 60 after bonding the polymer resistor 60 to the insulating substrate 101. The conductive strips 151 can be attached to the polymer resistor 60 in advance.

Linear electrodes 61 and polymer resistor 60 are thermally bonded. But the present invention is not limited to this. Linear electrodes 61 and polymer resistor 60 can also adhere by means of a conductive binder. The line electrodes 61 and the polymer resistor 60 can also be electrically connected by mechanical contact by simply pressing them together.

Option 6 implementation sheet heating element

FIG. 16A is a plan view of a sheet heating element 160 of Embodiment 6 of the present invention. FIG. 16B is a sectional view taken along line 16B-16B of FIG. 16A. The structure is different from that of Embodiment 4 (see FIGS. 14A, 14B) because the polymer resistor 161 is provided in place of the polymer resistor 60. The polymer resistor 161 is made by saturating the mesh non-woven fabric or woven fabric with a polymer resistor.

The sheet heating element 160 of Embodiment 6 is manufactured as follows. Ink is made by dispersing and mixing the polymer resistor described in Embodiments 1-5 in a liquid, such as a solvent. Mesh non-woven fabric or woven fabric is saturated with this printing ink by a method such as printing, dyeing, dipping or the like, and then dried to produce a polymer resistor 161. Mesh non-woven fabric or woven fabric has many small pores between the fibers, and the resistor The base resin seeps into these pores.

This polymer resistor 161 is then bonded to the insulating substrate 101 by hot lamination, then the line electrodes 61 are assembled on the polymer resistor 161 and sewn onto the insulating substrate 101 by a sewing machine. The linear electrodes 61 and the polymer resistor 161 are thermocompressed, so that the polymer resistor 161 adheres tightly to the linear electrodes 61.

In this design, since the polymer resistor 161 is formed of a mesh non-woven or woven fabric having many pores, it exhibits a high degree of flexibility, since it can easily change shape under the external force acting on it.

Since the polymer resistor is held within the pores in the nonwoven fabric or woven fabric, the polymer resistor 161 adheres tightly to the insulating substrate 101, thereby increasing the mechanical strength of the polymer resistor 161.

It should be noted that in this embodiment, the mesh non-woven fabric or woven fabric is saturated with a polymer resistor such as printing ink. It is also possible to subject the net non-woven fabric or woven fabric to a thermal compression treatment to saturate the non-woven fabric or woven fabric with a film or sheet type polymer resistor.

In addition, in this embodiment, the linear electrodes 61 and the polymer resistor 161 are thermally bonded. But the present invention is not limited to this. Linear electrodes 61 and polymer resistor 161 can also adhere by means of a conductive binder. The line electrodes 61 and the polymer resistor 161 can also be electrically connected by mechanical contact by simply pressing them together.

Moreover, in this embodiment, auxiliary linear electrodes 131 described in Embodiment 3 can also be provided (see FIG. 13A).

Option 7 implementation sheet heating element

FIG. 17A is a plan view of a sheet heating element 170 of Embodiment 7 of the present invention. FIG. 17B is a sectional view taken along line 17B-17B of FIG. 17A. The structure is different from that of Embodiment 1 (see FIGS. 10A, 10B) for the reason that the cover layer 171 is further provided on the polymer resistor 60.

The coating layer 171 is formed of a material having electrical insulation properties. After using hot lamination to lay the polymer resistor 60 on the insulating substrate 101, to which the linear electrodes 61 have already been attached, the coating layer 171 is also attached by hot lamination in order to cover the polymer resistor 60.

The coating layer 171 protects the sheet heating element 170 from shock and scratching, which can damage the polymer resistor 60.

In addition, when the heating element is used in a car seat heater or in conditions such as subjecting the heating element to constant sliding of a constant external force, the cover layer 171 prevents the polymer resistor 60 from abrasion, so the sheet heating element will not lose its heat dissipation function.

Moreover, since the sheet heating element 170 is electrically isolated, it is safe even if high voltage is applied to the sheet heating element 170.

A coating layer 171 must be provided in order to cover the polymer resistor 60 in its entirety. However, taking into account the flexibility, it is preferable to use a thin coating layer as the coating layer 171.

The coating layer 171 contains, as its main component, a polyolefin-based thermoplastic elastomer, a styrene-based thermoplastic elastomer, or a urethane-based thermoplastic elastomer, used alone, or a combination thereof, used as the main component. Thermoplastic elastomer gives flexibility to the sheet heating element 170.

It should be noted that the coating layer 171 can also be used in options 2-6 implementation described above.

Option 8 implementation sheet heating element

FIG. 18A is a plan view of a sheet heating element 180 of Embodiment 8 of the present invention. FIG. 18B is a sectional view taken along line 18B-18B of FIG. 18A. The structure is different from that of Embodiment 1 (see FIGS. 10A, 10B) because at least the insulating substrate 101 and / or the polymer resistor 60 are provided with a plurality of slots 181.

The sheet heating element 180 of Embodiment 8 is manufactured as described below. At the beginning, as in Embodiment 1, the linear electrodes 161 are assembled on and insulated to the insulating substrate 101. Using extrusion molding through a flat slot mouthpiece, the polymer resistor 60 is extruded as a film or sheet on an insulating substrate 101 and is thermally bonded to the linear electrodes and the insulating substrate 101. After punching the center of the insulating substrate 101 to form elongated holes, the Thompson punch is used to form a plurality of slots 181 in the polymer resistor 60 and the insulating substrate 101.

The places pierced by the Thompson punch are not limited to the places shown in the drawing. Depending on the shape of the seat cover 114, punching may be provided in places other than those shown in the drawing. In this case, it may be necessary to modify the wiring pattern of the linear electrodes 61.

In addition, the linear electrodes 61 and the polymer resistor 60 can be attached to an insulating substrate 101 on which slots 181 have already been formed, punched by the Thompson punch. Alternatively, the polymer resistor 60 may be attached to a separator, such as polypropylene or mold grease paper (not shown). Then, the slots 181 are formed in the polymer resistor 60 by punching before attaching to the insulating substrate 101. In the first case, the slots 181 are formed only in the insulating substrate 101, and in the latter case, the slots 181 are formed only in the polymer resistor 60.

Since a plurality of slots 181 are formed in the sheet heating element 180 of this embodiment, the sheet heating element 180 can easily change shape in response to an external force, so that a feeling of comfort is improved when sitting on it. An elongated hole formed in the central part of the insulating substrate 101 can also be considered as serving to give flexibility to the sheet heating element 180. However, an elongated hole is provided for attaching the sheet heating element 180 to the seat and is not intended to give flexibility to the sheet heating element 180. Therefore, it should be functionally distinguishable from slots 181.

It should be noted that the slots 181 of this embodiment can also be formed on sheet heating elements according to embodiments 1-7.

Option 9 implementation sheet heating element

FIG. 19A is a plan view of a sheet heating element 190 of Embodiment 9 of the present invention. FIG. 19B is a sectional view taken along line 19B-19B of FIG. 19A. The structure is different from that of Embodiment 8 (see FIGS. 10A, 10B) for the reason that a plurality of grooves 191 are provided in place of the slots 181.

The sheet heating element 190 of Embodiment 9 is manufactured as described below. First, the polymer resistor 60 is attached to a separator, such as polyurethane or mold grease paper (not shown), and the polymer resistor 60 is punched to form the grooves 191. Then, hot lamination is used to attach the polymer resistor 60 to the insulating substrate 101 on which wave-like linear electrodes 121 were arranged, after which the spacer was removed from the polymer resistor 60.

In this configuration, the linear electrodes 121 and the polymer resistor 60 are thermally bonded so as to be securely attached to each other. Since the polymer resistor 60 easily changes shape in response to an external force due to the grooves 191, the feeling of comfort is improved when sitting on it.

Moreover, such grooves 191 can be formed on the insulating substrate 101. In this case, these grooves 191 serve to a large extent the above-described function, making it possible to further improve the feeling of comfort when sitting on them.

The grooves 191 of this embodiment can also be formed in sheet heating elements according to embodiments 1-7.

It should be noted that the sheet heating elements described in Embodiments 2-9 can be fixed so that the insulating substrate is on the upper side if the seat portion 111 and the rear backrest 112 shown in FIG. 11A, 11B, as in the case of the sheet heating element 100 of Embodiment 1. The insulating substrate 101 serves as a cushion and no bulges are formed on the surface due to the thickness and stiffness of the linear electrodes 61. Accordingly, there is no loss of comfort when sitting or resting on the back.

INDUSTRIAL APPLICABILITY

The sheet heating element of the present invention has a simple structure, excellent PTC performance and is flexible in easily changing shape in response to an external force. Since this sheet heating element can be attached to surfaces of household appliances that have complex surface topologies, it can be used in heaters for the seats and steering wheel of a car, as well as in household appliances such as electric floor heaters that require heating. Moreover, the range of application is enormous due to excellent labor productivity and cost reduction.

LIST OF REFERENCE NUMBERS IN THE DRAWINGS

10, 30, 100, 120, 130, 140, 150, 160, 170, 180, 190 - sheet heating element,

11, 31, 101 - substrate,

12, 13, 32, 33 - electrode,

14, 34, 60, 161 - polymer resistor,

15, 35, 171 - coating layer,

20, 21 - hot drum,

22 - laminator

40, 64, 67 - conductors,

61, 121, 131 - linear electrode,

62, 65 - resistor composition,

41, 63, 66 - composition based on resin,

102, 132 - thread,

111 - part of the seat,

112 - backrest,

113 - seat base material,

114 - seat cover,

151 conductive strip

181 - slot

191 - groove.

Information sources

1. Publication No. S56-13689 of the unexamined patent application of Japan.

2. Publication No. H8-120182 of an unexamined Japanese patent application.

3. US patent, No. 7049559.

Claims (88)

1. Resistor with a positive temperature coefficient (RTS), comprising: at least one composition with RTS, containing at least one resin and at least two conductive materials, while at least two conductive materials contain at least two conductive materials different from each other, while at least one of the first and second resins contains at least one of a metal powder and a conductive non-metallic powder. 2. The resistor according to claim 1, in which at least one composition with RTS contains:
a first composition with PTC containing the first resin and at least one first conductive material; and
a second composition with RTS, compounding with the first composition with RTS and containing a second resin and at least a second conductive material,
wherein at least one first conductive material is at least partially different from at least one second conductive material. 3. The resistor according to claim 2, in which one of the first and second trains with RTS forms clusters that are distributed within the other of the first and second trains with RTS. 4. The resistor according to claim 2, in which one of the first and second compositions with RTS is contained in a resistor with RTS with a content of 20-80 wt.%. 5. The resistor according to claim 2, wherein said one of the first and second compositions with PTC is contained in a resistor with PTC with a content of 30-70 wt.%. 6. The resistor according to claim 2, wherein said one of the first and second compositions with PTC is contained in a resistor with PTC with a content of 40-60 wt.%. 7. The resistor according to claim 2, in which one of the first resin and the second resin contains a reagent resin and a reactive resin that crosslinkes with the reagent resin. 8. The resistor according to claim 7, in which the reagent resin contains a modified olefin resin. 9. The resistor of claim 8, wherein the modified olefin resin comprises an ester type ethylene copolymer. 10. The resistor of claim 9, wherein the ester type ethylene copolymer comprises any one of an ethylene / vinyl acetate copolymer, ethylene / ethyl acrylate copolymer, ethylene / methyl methacrylate copolymer, ethylene / methacrylic acid copolymer and ethylene / butyl acrylate copolymer. 11. The resistor according to claim 7, in which the reactive resin is contained with a content of 1-20 wt.% In the aforementioned one of the first resin and the second resin. 12. The resistor according to claim 7, in which the reactive resin is contained with a content of 1-10 wt.% In the aforementioned one of the first resin and the second resin. 13. The resistor according to claim 7, in which the reagent and reactive resins contain different components selected from the group consisting of carboxyl groups, carbonyl groups, hydroxyl groups, ester groups, vinyl groups, amine groups, epoxy groups, oxazoline groups and groups of maleic anhydride. 14. The resistor according to claim 7, in which the first and second resins have affinity for each other. 15. The resistor according to claim 7, in which the other of the first resin and the second resin contains components selected from the group consisting of carboxyl groups, carbonyl groups, hydroxyl groups, ester groups, vinyl groups, amine groups, epoxy groups, oxazoline groups and maleic anhydride groups. 16. The resistor according to claim 2, in which at least one of the first and second resins contains a thermoplastic elastomer. 17. The resistor of claim 16, wherein the thermoplastic elastomer comprises at least one of an olefin based thermoplastic elastomer based on a styrene thermoplastic elastomer based on a urethane based thermoplastic elastomer and a polyester based thermoplastic elastomer. 18. The resistor according to clause 16, in which the thermoplastic elastomer is contained with a content of 5-20 wt.% In at least one of the first and second resins. 19. The resistor according to claim 2, in which at least one first conductive material contains at least one kind of conductive material that is not contained in at least one second conductive material. 20. The resistor according to claim 2, in which at least one first conductive material contains carbon black, and at least one second conductive material contains graphite. 21. The resistor according to claim 2, in which at least one first conductive material and at least one second conductive material each contains at least one of carbon black, graphite, carbon nanotubes, carbon fibers, conductive ceramic fibers, conductive whiskers, metal fibers, conductive inorganic oxides and conductive polymer fibers. 22. The resistor according to claim 2, in which one of the at least one first conductive material and at least one second conductive material is contained with a content of 30-90 wt.% In the first or second composition with RTS, which contains at least one conductive material. 23. The resistor according to claim 2, in which one of the at least one first conductive material and at least one second conductive material is contained in a content of 40-80 wt.% In the first or second composition with RTS, which contains at least one conductive material. 24. The resistor according to claim 2, in which one of the at least one first conductive material and at least one second conductive material is contained in a content of 60-70 wt.% In the first or second composition with RTS, which contains at least one conductive material. 25. The resistor according to claim 2, in which the other one of at least one first conductive material and at least one second conductive material is contained in a content of 20-80 wt.% In the first or second composition with RTS, which contains at least at least one conductive material. 26. The resistor according to claim 2, in which the other one of at least one first conductive material and at least one second conductive material is contained in a content of 30-70 wt.% In the first or second composition with RTS, which contains at least at least one conductive material. 27. The resistor according to claim 2, in which the other one of at least one first conductive material and at least one second conductive material is contained in a content of 30-60 wt.% In the first or second composition with RTS, which contains at least at least one conductive material. 28. The resistor according to claim 2, wherein the RTS resistor has an electrical resistivity in the range between 0.0007 Ohm · m and 0.016 Ohm · m. 29. The resistor according to claim 2, while the resistor with RTS has an electrical resistivity in the range between 0.0011 Ohm · m and 0.0078 Ohm · m. 30. The resistor according to claim 2, wherein the PTC resistor exhibits an electrical resistivity at 50 ° C, which is at least two times higher than its electrical resistivity measured at 20 ° C. 31. The resistor according to claim 2, wherein at a temperature less than 50 ° C, a resistor with a PTC exhibits an electrical resistivity lower than the electrical resistivity of a first or second composition with a PTC, along with a demonstration, at a temperature above 50 ° C, electrical resistivity greater than those of the first and second compositions with RTS. 32. The resistor according to claim 2, while the resistor with the RTS is extended by no more than 5% at a load of less than 7 kgf. 33. The resistor according to claim 2, while the resistor with RTS has a coefficient of thermal expansion between 20 · 10 ^-5 / K and 40 · 10 ^-5 / K. 34. The resistor according to claim 2, in which at least one of the first and second compositions of the RTS contains an additive flame retardant. 35. The resistor of claim 34, wherein the flame retardant additive comprises at least one phosphorus-based flame retardant, nitrogen-based flame retardant, silicon-based flame retardant, inorganic flame retardant, and halogen-based flame retardant. 36. The resistor according to clause 34, in which the flame retardant additive is contained in a resistor with RTS with a content of 5 wt.% Or more. 37. The resistor according to clause 34, in which the flame retardant additive is contained in a resistor with RTS with a content of 10-30 wt.%. 38. The resistor according to clause 34, in which the flame retardant additive is contained in a resistor with RTS with a content of 15-25 wt.%. 39. The resistor according to claim 2, which contains a liquid-resistant resin. 40. The resistor according to claim 39, wherein the liquid-resistant resin is contained with a content of 10 wt.% Or more, as regards the first and second compositions with PTC. 41. The resistor according to clause 39, in which a liquid-resistant resin is contained with a content of 10-70 wt.%, As for the first and second compositions with RTS. 42. The resistor according to clause 39, in which the liquid-resistant resin is contained with a content of 30-50 wt.%, As for the first and second compositions with RTS. 43. The resistor of claim 39, wherein the liquid-resistant resin comprises at least one of ethylene / vinyl alcohol copolymer, thermoplastic polyester resin, polyamide resin, polypropylene resin and ionomer. 44. The resistor according to claim 7, in which the chemically active resin contains a liquid-resistant resin. 45. A resistor with a positive temperature coefficient (RTS), containing:
at least one composition with PTC, containing at least one resin and at least two conductive materials, while at least two conductive materials contain at least two conductive materials different from each other, at least one of at least one first conductive material and at least one second material is made in the form of flakes. 46. The resistor according to item 45, in which at least one composition with RTS contains:
a first composition with PTC containing the first resin and at least one first conductive material; and
a second composition with RTS, compounding with the first composition with RTS and containing a second resin and at least a second conductive material,
wherein at least one first conductive material is at least partially different from at least one second conductive material. 47. The resistor according to claim 46, wherein one of the first and second trains with RTS forms clusters that are distributed within the other of the first and second trains with RTS. 48. The resistor according to item 46, in which one of the first and second compositions with RTS is contained in a resistor with RTS with a content of 20-80 wt.%. 49. The resistor according to item 46, wherein said one of the first and second compositions with RTS is contained in a resistor with RTS with a content of 30-70 wt.%. 50. The resistor according to item 46, wherein said one of the first and second compositions with RTS is contained in a resistor with RTS with a content of 40-60 wt.%. 51. The resistor according to item 46, in which one of the first resin and the second resin contains a reagent resin and a reactive resin that crosslinkes with the reagent resin. 52. The resistor of claim 51, wherein the reagent resin comprises a modified olefin resin. 53. The resistor according to paragraph 52, in which the modified olefin resin contains an ethylene copolymer of the ester type. 54. The resistor of claim 53, wherein the ester-type ethylene copolymer comprises any one of an ethylene / vinyl acetate copolymer, ethylene / ethyl acrylate copolymer, ethylene / methyl methacrylate copolymer, ethylene / methacrylic acid copolymer and ethylene / butyl acrylate copolymer. 55. The resistor according to paragraph 51, in which the reactive resin is contained with a content of 1-20 wt.% In the aforementioned one of the first resin and the second resin. 56. The resistor according to paragraph 51, in which the reactive resin is contained with a content of 1-10 wt.% In the aforementioned one of the first resin and the second resin. 57. The resistor of claim 51, wherein the reagent and reactive resins contain different components selected from the group consisting of carboxyl groups, carbonyl groups, hydroxyl groups, ester groups, vinyl groups, amine groups, epoxy groups, oxazoline groups, and groups of maleic anhydride. 58. The resistor of claim 51, wherein the first and second resins have affinity for each other. 59. The resistor of claim 51, wherein the other of the first resin and the second resin contains components selected from the group consisting of carboxyl groups, carbonyl groups, hydroxyl groups, ester groups, vinyl groups, amine groups, epoxy groups, oxazoline groups and maleic anhydride groups. 60. The resistor according to item 46, in which at least one of the first and second resins contains a thermoplastic elastomer. 61. The resistor of claim 60, wherein the thermoplastic elastomer comprises at least one of an olefin based thermoplastic elastomer based on a styrene thermoplastic elastomer based on a urethane based thermoplastic elastomer and a polyester based thermoplastic elastomer. 62. The resistor according to claim 60, wherein the thermoplastic elastomer is contained with a content of 5-20 wt.% In at least one of the first and second resins. 63. The resistor of claim 46, wherein the at least one first conductive material comprises at least one kind of conductive material that is not contained in the at least one second conductive material. 64. The resistor according to item 46, in which at least one first conductive material contains carbon black, and at least one second conductive material contains graphite. 65. The resistor according to item 46, in which at least one first conductive material and at least one second conductive material each contains at least one of soot, graphite, carbon nanotubes, carbon fibers, conductive ceramic fibers, conductive whiskers, metal fibers, conductive inorganic oxides and conductive polymer fibers. 66. The resistor according to clause 47, in which one of at least one first conductive material and at least one second conductive material is contained in a content of 30-90 wt.% In the first or second composition with RTS, which contains at least one conductive material. 67. The resistor according to item 46, in which one of at least one first conductive material and at least one second conductive material is contained in a content of 40-80 wt.% In the first or second composition with RTS, which contains at least one conductive material. 68. The resistor according to item 46, in which one of at least one first conductive material and at least one second conductive material is contained in a content of 60-70 wt.% In the first or second composition with RTS, which contains at least one conductive material. 69. The resistor according to item 46, in which the other one of at least one first conductive material and at least one second conductive material is contained in a content of 20-80 wt.% In the first or second composition with RTS, which contains at least at least one conductive material. 70. The resistor according to item 46, in which the other one of at least one first conductive material and at least one second conductive material is contained in a content of 30-70 wt.% In the first or second composition with RTS, which contains at least at least one conductive material. 71. The resistor according to item 46, in which the other one of at least one first conductive material and at least one second conductive material is contained in a content of 30-60 wt.% In the first or second composition with RTS, which contains at least at least one conductive material. 72. The resistor according to item 46, wherein the RTS resistor has an electrical resistivity in the range between 0.0007 Ohm · m and 0.016 Ohm · m. 73. The resistor according to item 46, wherein the resistor with RTS has an electrical resistivity in the range between 0.0011 Ohm · m and 0.0078 Ohm · m. 74. The resistor of claim 46, wherein the PTC resistor exhibits an electrical resistivity at 50 ° C, which is at least two times higher than its electrical resistivity measured at 20 ° C. 75. The resistor according to item 46, wherein at a temperature less than 50 ° C, a resistor with a PTC exhibits an electrical resistivity lower than an electrical resistivity of a first or second composition with a PTC, along with a demonstration, at a temperature above 50 ° C, electrical resistivity greater than those of the first and second compositions with RTS. 76. The resistor according to claim 46, wherein the resistor with the RTS extends no more than 5% at a load of less than 7 kgf. 77. The resistor according to item 46, wherein the resistor with RTS has a coefficient of thermal expansion between 20 · 10 ^-5 / K and 40 · 10 ^-5 / K. 78. The resistor according to item 46, in which at least one of the first and second compositions of the RTS contains an additive flame retardant. 79. The resistor of claim 78, wherein the flame retardant additive comprises at least one phosphorus-based flame retardant, nitrogen-based flame retardant, silicon-based flame retardant, an inorganic flame retardant, and halogen-based flame retardant. 80. The resistor of claim 78, wherein the flame retardant is contained in a resistor with a PTC with a content of 5% by weight or more. 81. The resistor according to claim 78, in which the flame retardant additive is contained in a resistor with a PTC with a content of 10-30 wt.%. 82. The resistor according to claim 78, in which the flame retardant additive is contained in a resistor with a PTC with a content of 15-25 wt.%. 83. The resistor of claim 78, which comprises a liquid-resistant resin. 84. The resistor of claim 83, wherein the liquid-resistant resin is contained with a content of 10 wt.% Or more, as regards the first and second formulations with PTC. 85. The resistor of claim 83, wherein the liquid-resistant resin is contained with a content of 10-70 wt.%, As for the first and second compositions with RTS. 86. The resistor of claim 83, wherein the liquid-resistant resin is contained in a content of 30-50 wt.%, As for the first and second compositions with RTS. 87. The resistor of claim 83, wherein the liquid-resistant resin comprises at least one of ethylene / vinyl alcohol copolymer, thermoplastic polyester resin, polyamide resin, polypropylene resin and ionomer. 88. The resistor of claim 51, wherein the reactive resin comprises a liquid-resistant resin.

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