WO2008041790A1 - Coating apparatus of plane-shaped carbon heating unit and coating method thereof - Google Patents

Coating apparatus of plane-shaped carbon heating unit and coating method thereof Download PDF

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Publication number
WO2008041790A1
WO2008041790A1 PCT/KR2007/001916 KR2007001916W WO2008041790A1 WO 2008041790 A1 WO2008041790 A1 WO 2008041790A1 KR 2007001916 W KR2007001916 W KR 2007001916W WO 2008041790 A1 WO2008041790 A1 WO 2008041790A1
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WO
WIPO (PCT)
Prior art keywords
roller
film sheet
urethane
heating unit
pet
Prior art date
Application number
PCT/KR2007/001916
Other languages
French (fr)
Inventor
Hyun-Sik Hwang
Original Assignee
Jirehvision Co., Ltd.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Jirehvision Co., Ltd. filed Critical Jirehvision Co., Ltd.
Publication of WO2008041790A1 publication Critical patent/WO2008041790A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/26—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer which influences the bonding during the lamination process, e.g. release layers or pressure equalising layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/08—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the cooling method
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B32B37/20—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of continuous webs only
    • B32B37/203—One or more of the layers being plastic
    • B32B37/206—Laminating a continuous layer between two continuous plastic layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B43/00—Operations specially adapted for layered products and not otherwise provided for, e.g. repairing; Apparatus therefor
    • B32B43/006—Delaminating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/26—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer which influences the bonding during the lamination process, e.g. release layers or pressure equalising layers
    • B32B2037/268—Release layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/34—Inserts
    • B32B2305/345—Heating elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/02—Temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2313/00—Elements other than metals
    • B32B2313/04—Carbon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2367/00—Polyesters, e.g. PET, i.e. polyethylene terephthalate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2375/00—Polyureas; Polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings
    • B32B2471/02—Carpets

Definitions

  • the present invention relates to a coating apparatus of a plane-shaped carbon heating unit and a coating method thereof, and more particularly, to a coating apparatus of a plane-shaped carbon heating unit for coating a urethane film sheet on both sides of the plane-shaped carbon heating unit, and a coating method thereof.
  • plane-shaped heating bodies are heated by resistance of applied power and has been used in various fields such as electrical carpets, bottom materials, and instant cool-water warming devices.
  • Plane-shaped heating bodies have been developed to solve problems of conventional heating bodies which have a narrow cross-section of an electrothermal wire and a small heating area and in which an electrothermal wire in which heat is not uniformly transmitted is used.
  • Conventional plane-shaped carbon heating bodies generally comprise a heating unit formed of paper and including a carbon printing layer formed as carbon is printed on its surface, at least two electrode bodies which are formed in a thin plate shape, are provided on the heating unit and transmit (+) and (-) polarities, and an insulating body which is coated on its surface so as to prevent a safety accident such as an electric shock caused by an electric leakage.
  • Such a plane-shaped carbon heating unit is constituted in such a way that carbon is printed on the surface of a heating unit formed of paper, to form a carbon printing layer, an electrode body is simply arranged on the heating unit, an insulating body is compressed and coating on the surface of the electrode body so that the insulating body compresses the electrode body and the electrode body and the heating unit face each other and are electrically connected.
  • a coated insulating body is easily come off by a stress such as repetitive use and shape deformation, the electrode body is not easily compressed, a clearance is generated between the plane-shaped heating unit and the electrode body and an electrical contact becomes bad and cracks occur in the carbon printing layer of the plane-shaped heating unit having no elasticity and an electrical contact may become bad.
  • the plane-shaped carbon heating unit is a woven fabric and is dyed with a carbon solution and comprises an electrode body of a thin copper or metal thin plate that is attached to both ends of the plane-shaped heating unit and therebetween using a carbon adhesive and an insulating body for coating the surface of the plane-shaped heating unit to which the electrode body is attached.
  • the electrode bodies are attached to both ends of the plane-shaped heating unit and therebetween using the carbon adhesive.
  • the electrode bodies are electrically connected to an external power source and transmit (+) and (-) polarities to the plane-shaped heating unit and the plane-shaped heating unit is heated by resistance which is an electrical characteristic.
  • the conventional plane-shaped carbon heating unit coats the surface with urethane so as to prevent a safety accident such as an electric shock caused by an electrical leakage.
  • urethane coating with respect to fibers is performed by a process in which a urethane raw material (a urethane ball) is heated and molten in a hoper, urethane of the molten hoper is coated on the surface of a raw cloth transmitted from the lower portion of the hoper and is cooled.
  • a urethane raw material a urethane ball
  • urethane of the molten hoper is coated on the surface of a raw cloth transmitted from the lower portion of the hoper and is cooled.
  • the plane-shaped carbon heating unit when the plane-shaped carbon heating unit is coated with urethane, a troublesome process in which waste of the urethane raw material caused by coating of the molten urethane is serious and the thickness of a coating layer is not uniform, and after urethane is coated on the upper surface of the plane-shaped carbon heating unit and is cooled after a predetermined amount of time and the lower surface of the plane-shaped carbon heating unit is coated, should be performed. Thus, a coating process is lengthened.
  • the plane-shaped carbon heating unit is used in places in which there are many contacts and shape deformation.
  • coating is performed by simple coating and cooling in the coating process and the cooling process.
  • the shape of the plane-shaped carbon heating unit is deformed, a problem that the plane-shaped carbon heating unit and the urethane coating layer are come off occurs and the reliability of a product is lowered.
  • a plane-shaped carbon heating unit 1 coated by a method of coating urethane is sold or used in units of a predetermined length.
  • a heating unit 1a and an electrode 1 b are exposed from a cut surface S, as shown in FIG. 7 and a problem such as an electric leakage occurs.
  • several methods for heating and compressing a urethane film have been suggested. However, if a urethane film sheet is heated at a coating temperature, the urethane film sheet is very easily elongated.
  • the urethane film sheet is coated on the plane-shaped carbon heating unit, due to a difference between the elongated surface area by heating and temperature distribution of the plane-shaped carbon heating unit and the electrode body, the urethane film sheet is pushed out from the surface of the plane-shaped carbon heating unit during coating or bubbles are generated.
  • a defective rate increases and productivity is seriously lowered so that there are no profits by enforcement and actually, enforcement is not possible.
  • the objective of the present invention is to provide a coating apparatus of a plane-shaped carbon heating unit in which urethane film sheets are heated at a higher temperature than the melting point of urethane, problems that may occur by a temperature difference between the plane-shaped carbon heating unit and an electrode body and a change in surface caused by elongation of the urethane film sheets are solved and the urethane film sheets are simultaneously heated and compressed on upper and lower surfaces of the plane-shaped carbon heating unit, and a coating method thereof.
  • the present invention provides a coating apparatus of a plane-shaped carbon heating unit, the apparatus comprising: upper and lower urethane rollers which are installed to be freely rotated in upper and lower predetermined positions, respectively, of one side of a panel comprised of a plurality of horizontal and vertical frames and in which bobbins around which urethane film sheets each having a predetermined width are wound are respectively inserted and combined; upper and lower PET rollers which are installed to be freely rotated in the upper and lower predetermined positions of one side of the panel and in which bobbins around which PET film sheets each having a predetermined width are wound are respectively inserted and combined; a heating unit of a film sheet which heats a urethane film sheet of the upper urethane roller, a PET film sheet of the upper PET roller, a urethane film sheet of the lower urethane roller, and a PET film sheet of the lower PET roller; a pressure roller which presses the upper and lower urethane
  • a coating apparatus of a plane-shaped carbon heating unit comprising: upper and lower urethane rollers which are installed to be freely rotated in upper and lower predetermined positions, respectively, of one side of a panel comprised of a plurality of horizontal and vertical frames and in which bobbins around which urethane film sheets each having a predetermined width are wound are respectively inserted and combined; upper and lower PET rollers which are installed to be freely rotated in the upper and lower predetermined positions of one side of the panel and in which bobbins around which PET film sheets each having a predetermined width are wound are respectively inserted and combined; a heating unit of a film sheet which heats a urethane film sheet of the upper urethane roller, a PET film sheet of the upper PET roller, a urethane film sheet of the lower urethane roller, and a PET film sheet of the lower PET roller; a heating unit supply roller which is installed to be freely rotated in a predetermined position of one
  • the heating unit of the film sheet may comprise: a first guide roller which is installed in a predetermined position of the panel and guides the urethane film sheet supplied by the lower urethane roller to overlap an upper portion of the PET film sheet supplied by the lower PET roller; a second guide roller which is installed in a predetermined position of the panel and guides the PET film sheet supplied by the upper PET roller to overlap an upper portion of the urethane film sheet supplied by the upper urethane roller; a first heating roller which is installed to be closely attached to the first guide roller in a predetermined position of the panel and in which a heating member that allows the urethane film sheet and the PET film sheet guided by the first guide roller and closely attached to the outer diameter surface of the first heating roller to be heated at a predetermined temperature and conveyed; and a second heating roller which is installed adjacent to the other-side panel of the first heating roller and in which a heating member that allows the urethane film sheet and the PET film sheet guided by the second guide roller and closely attached to the outer diameter surface of the second heating
  • the heating member may be a heating coil which is built in a drum of the first heating roller or the second heating roller to heat the drum.
  • the cooling member may comprise: a plurality of cooling flow paths which are formed in the drum of the cooling roller; and a cooling water circulating device which is installed distant from the panel so as to supply and discharge the cooling water into the cooling flow paths.
  • the apparatus may further comprise: a first interlocking sprocket which is installed in at least one end of the first heating roller and the pressure roller; a first driving motor in which a driving sprocket is shaft-inserted so that the first driving motor can be connected to the first interlocking sprocket by a chain and which is installed on the panel to generate power; a second interlocking sprocket which is shaft-inserted in one of shafts of the first heating roller and the pressure roller in which the first interlocking sprocket is shaft-inserted; and a third interlocking sprocket which is installed in one end of the pressure roller and the first heating roller to be connected to the second interlocking sprocket by a chain.
  • the apparatus may further comprise: a rotative bracket which is surrounded on outsides of a shaft so that shafts of both ends of the first guide roller and the second guide roller can be rotated freely; a guide bracket in which a guide groove is formed inside of both-sides of the guide bracket so that both ends of the rotative bracket are inserted in the guide groove and ascend and descend by a predetermined inclination upwards and downwards and in which a screw hole is formed in one of upper and lower ends of the guide bracket; and a lead screw which is combined with the screw hole of the guide bracket so that the lead screw is freely rotated at one of upper and lower ends of the rotative bracket.
  • the separating unit of the film sheet may comprise: a lower PET winding roller which is installed in a predetermined position of a lower portion of the panel at the other side of the cooling roller so that the PET film sheet under the urethane film sheet cooled by the cooling roller is separated from the urethane film sheet and is wound therearound; an upper PET winding roller which is installed in a predetermined position of an upper portion of the panel at the other side of the cooling roller so that the PET film sheet on the urethane film sheet cooled by the cooling roller is separated from the urethane film sheet and is wound therearound; and a heating unit winding roller which is installed in a predetermined position of the panel at the other side of the cooling roller so that the plane-shaped carbon heating unit in which the upper and lower PET film sheets are separated from each other by the upper and lower PET winding rollers and the urethane film sheet is coated, is wound on the heating unit winding roller.
  • a power transmission member may be installed at one end of the upper and lower PET winding rollers and the heating unit winding roller, respectively, to be rotated by second, third, and fourth driving motors installed on the panel.
  • the apparatus may further comprise a compression roller which is installed on the panel to be ascended and descended at a predetermined angle at the outer diameter surface of the other side of the heating roller so that the PET film sheet passing the pressure roller and the second heating roller and the fused urethane film sheet are closely attached to a predetermined region of the outer diameter surface of the pressure roller and is rotated and compress the urethane film sheet.
  • the apparatus may further comprise: a first interlocking gear which is shaft-inserted in one of both ends of the second heating roller; and a second interlocking gear which is shaft-inserted in the pressure roller so as to be meshed with the first interlocking gear.
  • a method of coating a plane-shaped carbon heating unit comprising: a paper-combining process in which upper and lower urethane film sheets are closely attached to upper and lower surfaces of a woven plane-shaped carbon heating unit and PET film sheets are closely attached to an upper surface of the upper urethane film sheet and a lower surface of the lower urethane film sheet; a heating process in which some of the upper and lower PET film sheets, the upper and lower urethane film sheets, and the plane-shaped carbon heating unit that are combined in the paper-combining process are surrounded on outsides of a heating roller in which a heating member is built; a fusing process in which the upper and lower PET film sheets, the upper and lower urethane film sheets, and the plane-shaped carbon heating unit that are heated in the heating process are pressed so that the upper and lower urethane film sheets and the plane-shaped carbon heating unit are fused; a cooling process in which some of the upper and lower PET film sheets conveyed in the
  • one surface of the upper and lower urethane film sheets that contact the upper and lower PET film sheets may be coated with an adhesive to be release-paper-processed.
  • FIG. 1 illustrates a coating apparatus of a plane-shaped carbon heating unit according to an embodiment of the present invention.
  • FIG. 2 illustrates a coating apparatus of a plane-shaped carbon heating unit according to another embodiment of the present invention.
  • FIG. 3 illustrates the state where the plane-shaped carbon heating unit according to the present invention is coated with urethane.
  • FIG. 4 illustrates a guide bracket and a rotation bracket according to the present invention.
  • FIG. 5 illustrates a roll of the plane-shaped carbon heating unit to which a copper plate is combined.
  • FIG. 6 illustrates the state where a conventional plane-shaped carbon heating unit is coated with urethane.
  • FIG. 7 illustrates the state where the conventional coated plane-shaped carbon heating unit is cut.
  • FIGS. 1 through 5 A coating apparatus of a plane-shaped carbon heating unit and a coating method thereof according to the present invention will now be described with reference to FIGS. 1 through 5.
  • a panel for constituting a coating apparatus of a plane-shaped carbon heating unit are assembled using a plurality of general horizontal and vertical frames and are not limited to its shape and structure.
  • the panel for constituting a coating apparatus of a plane-shaped carbon heating unit may be installed to rotate freely in a predetermined position in the state where bearings are surrounded on outsides of shafts of upper and lower urethane rollers 101a and 101 b, upper and lower PET rollers 102a and 102b, a first heating roller 111 , a second heating roller 112, a pressure roller 106, a first guide roller 109, a second guide roller 1 10, and a compression roller 125.
  • FIGS. 1 and 2 schematically illustrate the coating apparatus of the plane-shaped carbon heating unit according to first and second embodiments of the present invention.
  • a difference in constructions between the first and second embodiments of the present invention is that, in the second embodiment, a heating unit supply roller 108 is added to the construction of the first embodiment, in the first embodiment, the plane-shaped carbon heating unit 105 having a predetermined length is supplied by a unit length and in the second embodiment, the plane-shaped carbon heating unit 105 is wound around a bobbin and is continuously supplied.
  • the plane-shaped carbon heating unit 105 may be woven and comprises a plane-shaped carbon heating unit in which an electrode plate 105a is attached to one of both ends of the plane-shaped carbon heating unit 105 and a plane-shaped carbon heating unit in which the electrode plate 105a is not attached to any one of both ends of the plane-shaped carbon heating unit 105.
  • upper and lower urethane rollers 101a and 101 b are installed at one-side upper and lower portions of a panel so that a bobbin around which a urethane film sheet to be closely coated (fused) on upper and lower surfaces of the plane-shaped carbon heating unit is wound can be mounted on the upper and lower urethane rollers 101a and 101 b.
  • bearings are generally surrounded on outsides of shafts of both ends of rollers according to the present invention, and the bearings are installed on a panel so that rotation of the rollers can be easily performed, as well known. Thus, a detailed description thereof will be omitted.
  • Upper and lower PET rollers 102a and 102b are installed in a position that is separated from the upper and lower urethane rollers 101a and 101 b by a predetermined distance, respectively.
  • bobbins around which PET film sheets 104a and 104b are wound are inserted and installed in the upper and lower PET rollers 102a and 102b, respectively.
  • Urethane film sheets 103a and 103b and PET film sheets 104a and 104b of the upper and lower urethane rollers 101a and 101 b and the upper and lower PET rollers 102a and 102b are heated and compressed respectively or simultaneously by first and second heating rollers 111 and 112 in which heating elements are built, as shown in FIG. 1.
  • first and second heating rollers 111 and 112 in which heating elements are built, as shown in FIG. 1.
  • the urethane film sheet 103b of the lower urethane roller 101 b and the PET film sheet 104b of the lower PET roller 102b are heated by the first heating roller 111
  • the urethane film sheet 103a of the upper urethane roller 101a and the PET film sheet 104a of the upper PET roller 102a are heated by the second heating roller 112.
  • the heating elements may be heating coils (electrothermal wires)(not shown) which are built in drums of the first heating roller 111 and the second heating roller 112 to heat the drums (outer diameter surfaces) or burners.
  • the heating elements built in the drums are well known.
  • the present invention is not limited to the above-described heating coils but may constitute the first and second heating rollers 111 and 112 by adopting various methods.
  • the first heating roller 111 is installed in a predetermined position between the upper and lower urethane rollers 101a and 101b and between the upper and lower PET rollers 102a and 102b, and the second heating roller 112 is installed adjacent to the first heating roller 111.
  • a first guide roller 109 is installed to be closely attached to the outer diameter surface of the first heating roller 111 so that the urethane film sheet 103b of the lower urethane roller 101 b and the PET film sheet 104b of the lower PET roller 102b are guided to the first guide roller 109 and is rotated and conveyed along the outer diameter surface of the first heating roller 111.
  • the first guide roller 109 is closely attached to the outer diameter surface of the first heating roller 111 in a lower predetermined position of the first heating roller 111 , and the urethane film sheet 103b and the PET film sheet 104b guided to the first guide roller 109 are wound in a predetermined region of the outer diameter surface of the first heating roller 111 and is rotated and conveyed upwards so that thermal conductivity is increased and the urethane film sheet 103b is sufficiently heated by the first heating roller 111.
  • the second heating roller 112 installed to be adjacent to the first heating roller 111 is installed at the adjacent other side, as shown in FIG. 1.
  • a second guide roller 110 is installed so that, as the urethane film sheet 103b of the lower urethane roller 10b and the PET film sheet 104b of the lower PET roller 102b are guided to the first guide roller 109 installed to be closely attached to the first heating roller 111 , they are closely attached to the second heating roller 112.
  • the second heating roller 112 allows the urethane film sheet 103a of the upper urethane roller 101a and the PET film sheet 104a of the upper PET roller 102a are guided to the second guide roller 110 and are wound in a predetermined region of the outer diameter surface of the second heating roller 112 and are rotated and conveyed downwards.
  • PET rollers 102a and 102b are directly closely attached to the outer diameter surfaces of the second heating roller 112 and the first heating roller 111 and can be directly heated by the second heating roller 112 and the first heating roller 111. They are guided to the second guide roller 110 and the first guide roller 109, and the urethane film sheets 103a and 103b of the upper and lower urethane rollers 101a and 101 b overlap the PET film sheets 104a and 104b and are indirectly closely attached to the outer diameter surfaces of the second heating roller 112 and the first heating roller 111 , are guided to the second guide roller 110 and the first guide roller 109 and are indirectly heated by the second heating roller 112 and the first heating roller 111.
  • the first heating roller 111 allows the urethane film sheet 103b to be rotated and conveyed upwards
  • the second heating roller 112 allows the urethane film sheet 103b to be rotated and conveyed downwards.
  • the upper and lower urethane film sheets 103a and 103b are disposed in the center of the combined paper
  • the PET film sheets 104a and 104b are disposed on and below the upper and lower urethane film sheets 103a and 103b.
  • the upper urethane film sheet 103a and the upper PET film sheet 104a which allow a pressure roller 106 to be closely installed to the lower portion of the second heating roller 112, are heated by the second heating roller 112 and are rotated and conveyed downwards, the lower urethane film sheet 103b and the upper and lower PET film sheets 104a and 104b which are heated by the first heating roller 111 , are rotated and conveyed upwards and are conveyed to the second heating roller 112, pass between the pressure roller 106 and the second heating roller 112 and are pressurized and fused, as shown in FIG. 1.
  • the plane-shaped carbon heating unit 105 which is cut by a unit length is supplied and seated by a predetermined supply unit at the upper surface of the urethane film sheet 103b which is heated and conveyed by the first heating roller 111 , as shown in FIG. 1 , so that the heated lower urethane film sheet 103b and the plane-shaped carbon heating unit 105 can be together conveyed and the plane-shaped carbon heating unit 105 can be disposed between the heated lower urethane film sheet 103b and the heated upper urethane film sheet 103a which is heated by the second heating roller 112.
  • the present invention is not limited to the above-described supply unit and a user may put the plane-shaped carbon heating unit 105 cut by a predetermined length on the upper surface of the lower urethane film sheet 103b which is conveyed from the second heating roller 112.
  • the plane-shaped carbon heating unit 105 is disposed between the upper and lower urethane film sheets 103a and 103b which pass between the second heating roller 112 and the pressure roller 106 so that the plane-shaped carbon heating unit 105 can be coated by the upper and lower urethane film sheets 103a and 103b.
  • the compression roller 125 is closely attached to a predetermined position of an outer diameter surface of the other side of the pressure roller 106, as shown in FIG. 1.
  • the urethane film sheets which are fused by heating and compression by the second heating roller 112 and the pressure roller 106 may be wound around a predetermined region of the pressure roller 106 and may be rotated and conveyed to improve a fusion rate.
  • the urethane film sheets according to the present invention are heated by the first heating roller 111 and the second heating roller 112 and are heated and compressed by the second heating roller 1 12, the pressure roller 106, and the compression roller 125 so that the upper and lower urethane film sheets 103a and 103b can be fused.
  • the melting point of a traditional urethane film sheet is 14O 0 C .
  • the urethane film sheet (polyurethane) is heated by a heating roller to over 140 0 C , as mentioned in the prior art, the urethane film sheet is elongated and its surfaces becomes irregularly uneven. Thus, even when it is compressed by the pressure roller 106 and the compression roller 125, bubbles enter the fused surface or it is pulled and wrinkles are generated.
  • the urethane film sheets when the urethane film sheets are heated, PET film sheets having a melting point of 225 ° C-265 ° C are directly heated by the first heating roller 1 1 1 and the second heating roller 1 12 to a proper temperature in which the PET film sheet is not elongated.
  • the urethane film sheets 103a and 103b which are conveyed while overlapping the PET film sheets 104a and 104b are indirectly heated to a high temperature near to 140 ° C .
  • urethane film sheets 103a and 113b and the PET film sheets 104a and 104b are heated at a high temperature, a minor temperature difference between the plane-shaped carbon heating unit 105 and the electrode plate 105a attached thereto does not affect conditions for fusing the upper and lower urethane film sheets 103a and 103b so that problems caused by a fusion rate or a coating defective rate due to the temperature difference can be completely solved.
  • the upper and lower PET film sheets 104a and 104b which pass the first and second heating rollers 111 and 112 and the pressure roller 106 and the compression roller 125, respectively, are not heated by the first and second heating rollers 111 and 112 up to the melting point of the PET film sheet.
  • the PET film sheets 104a and 104b are not fused on the upper and lower urethane film sheets 103a and 103b and are maintained while only overlapping each other.
  • the urethane film sheet which is fused by the pressure roller 106 and the compression roller 125, and the upper and lower PET film sheets 104a and 104b which are conveyed while overlapping upper and lower surfaces of the urethane film sheet, are installed adjacent to the pressure roller 106 and the compression roller 125, some of them are surrounded on outsides of a cooling roller 107 in which a cooling member is built and are rotated and conveyed, and as such, they are cooled.
  • the cooling member is installed on the panel or distant from the panel.
  • the cooling member may comprise a cooling water circulating device (not shown) having a pump for conveying a cooling water forcibly and a supply pipe for conveying the cooling water to the cooling roller 107 and a plurality of cooling flow paths (not shown) which are formed inside a drum of the cooling roller 107.
  • the above-described cooling member may also be used by adopting a well-known technology, like the heating member, and the present invention is not limited to this and may adopt and change various technologies.
  • the upper and lower PET film sheets 104a and 104b which are cooled by the cooling roller 107, the upper and lower urethane film sheets 103a and 103b which are fused therebetween, and the plane-shaped carbon heating unit 105 are separated by upper and lower PET winding rollers 123b and 123a and a heating unit winding roller 124 from one another.
  • the upper and lower PET winding rollers 123b and 123a may be installed to be spaced apart from the other side of the cooling roller 107 by a predetermined distance so that minor heat generated in the PET film sheet and the urethane film sheet passing the cooling roller 107 can be completely cooled at a room temperature.
  • the conveyed upper and lower PET film sheets 104a and 104b are separated from each other and wound around the upper and lower PET winding rollers 123b and 123a, and after the upper and lower PET film sheets 104a and 104b are separated from each other, the plane-shaped carbon heating unit 105 which is coated with the urethane film sheets 103a and 103b is guided to the heating unit winding roller 124 and is wound therearound.
  • a power transmission member (a pulley or a sprocket that can be combined with a belt or a chain) is installed at one end of the upper and lower PET winding rollers 123b and 123a and the heating unit winding roller 124 and can be rotated by second, third, and fourth driving motors (not shown) installed on the panel so that the urethane film sheets 103a and 103b of the upper and lower urethane rollers 101a and 101b and the PET film sheets 104a and 104b of the upper and lower PET rollers 102a and 102b can be conveyed in other direction according to a coating process.
  • a power transmission member a pulley or a sprocket that can be combined with a belt or a chain
  • a first interlocking sprocket 113 is shaft-inserted in at least one end of the first heating roller 111 and the pressure roller 106, and a driving sprocket 114 is shaft-inserted in a first driving motor 115 that is installed on the panel and generates power, to be connected to the first interlocking sprocket 113 by a chain.
  • the first heating roller 111 or the pressure roller 106 is rotated by the first driving motor 115, and a second interlocking sprocket 116 and a third interlocking sprocket 117 are shaft-inserted in the first heating roller 111 and the pressure roller 106, respectively, so that the first heating roller 111 and the pressure roller 106 can be interlocked with each other and then the second interlocking sprocket 116 and the third interlocking sprocket 117 can be connected to each other by a chain so that all of the first heating roller 111 and the pressure roller 106 can be rotated by the first driving motor 115.
  • a rotative force of the first driving motor 115 may be transmitted to the pressure roller 106, and the rotative force transmitted to the pressure roller 106 may be transmitted to the first heating roller 111.
  • a first interlocking gear (not shown) is shaft-inserted in one of both ends of the second heating roller 112
  • a second interlocking gear (not shown) is shaft-inserted in the pressure roller 106 to be meshed with the first interlocking gear so that the first heating roller 111 , the second heating roller 112, and the pressure roller 106 can heat, press, and convey the upper and lower urethane film sheets 103a and 103b, the upper and lower PET film sheets 104a and 104b, and the plane-shaped carbon heating unit 105 using the first driving motor 115 at the same rotation speed.
  • the first guide roller 109, the second guide roller 110, and the compression roller 125 are installed on the panel to be closely attached to outer diameter surfaces of the first heating roller 111 , the second heating roller 112, and the pressure roller 106, respectively.
  • the first guide roller 109, the second guide roller 110, and the compression roller 125, which are closely attached to the outer diameter surfaces of the first heating roller 111 , the second heating roller 112, and the pressure roller 106 are spaced apart from one another by a predetermined distance so that the upper and lower urethane film sheets 103a and 103b and the upper and lower PET film sheets 104a and 104b can be connected to respective rollers installed on the panel. As such, preparation for work for passing film sheets therebetween can proceed smoothly.
  • a rotative bracket 118 is surrounded on outsides of a shaft and is installed at the shaft so that shafts of the first guide roller 109, the second guide roller 110, and the compression roller 125 can be rotated freely, and the rotative bracket 118 comprises a bearing that is surrounded on outsides of the shaft and is installed at the shaft.
  • a guide groove 119 is formed at inner both sides of a guide bracket 121 , which is installed on the panel and ascends and descends the rotative bracket 118 in a vertical direction or in a slant line direction, as shown in FIGS. 1 and 4, so that both ends of the rotative bracket 118 are inserted in the guide groove 119 and guided thereto.
  • a screw hole 120 is formed in one of upper and lower ends of the guide bracket 121 , and a lead screw 122 is combined with the screw hole 120 so as to be connected to the screw hole 120 and to be freely rotated at one of upper and lower ends of the rotative bracket 118.
  • the lead screw 122 when the lead screw 122 is rotated, the lead screw 122 ascends and descends along the screw hole 120, and the rotative bracket 118 is ascended and descended together so that the first guide roller 109, the second guide roller 110, and the compression roller 125 can be spaced apart from or be closely attached to the first heating roller 111 , the second heating roller 112, and the pressure roller 106, respectively.
  • a second embodiment of the present invention is the same as the first embodiment of the present invention with respect to the structure and operation.
  • the heating unit supply roller 108 is installed at one side of the panel so that the roll-shaped and plane-shaped carbon heating unit 105 shown in FIG. 5 can be continuously supplied between the upper and lower urethane film sheets 103a and 103b.
  • a bobbin around which the plane-shaped carbon heating unit 105 having a predetermined width is wound is inserted in and combined with the heating unit supply roller 108.
  • the plane-shaped carbon heating unit 105 can be supplied between the first heating roller 1 11 and the second heating roller 1 12 directly from the heating unit supply roller 108.
  • a difference between the first and second embodiments of the present invention is that, as the plane-shaped carbon heating unit 105 that is cut by a unit length if necessary is supplied between the upper and lower urethane film sheets 103a and 103b at regular intervals, all outer edges of the plane-shaped carbon heating unit 105 can be coating with a urethane film sheet 103c, as shown in FIG. 3.
  • the plane-shaped carbon heating unit 105 is continuously supplied by the heating unit supply roller 108 shown in FIG. 2 or the plane-shaped carbon heating unit 105 is supplied by a predetermined supply unit at predetermined intervals.
  • a paper-combining process in which the urethane film sheets 103a and 103b of the upper and lower urethane rollers 101a and 101 b and the PET film sheets 104a and 104b of the upper and lower PET rollers 102a and 102b are supplied and conveyed so as to be closely attached to upper and lower portions of the plane-shaped carbon heating unit 105, is performed.
  • a heating process in which the upper and lower PET film sheets 104a and 104b, some of the upper and lower urethane film sheets 103a and 103b, and the plane-shaped carbon heating unit 105, which are combined with one another in the paper-combining process, are surrounded on outsides of the heating rollers 111 and 112 in which heating members are built, and are conveyed, is performed.
  • the upper urethane film sheet 103a is closely attached to the upper portion of the upper PET film sheet 104a
  • the lower urethane film sheet 103b is closely attached to the upper portion of the lower PET film sheet 104b.
  • the guide rollers 109 and 110 are installed to be closely attached to the outer diameter surfaces of the heating rollers 111 and 112 so that the urethane film sheets 103a and 103b can be indirectly heated.
  • a fusing process in which, after the upper and lower PET film sheets 104a and 104b, the upper and lower urethane film sheets 103a and 103b, and the plane-shaped carbon heating unit 105, which are heated in the heating process, pass a pair of pressure rollers 106 to be pressurized or one of the heating rollers 111 and 112 and the pressure roller 106 are closely attached to one another, the upper and lower urethane film sheets 103a and 103b which are heated by passing therebetween and the plane-shaped carbon heating unit 105 disposed therebetween are fused, is performed.
  • the urethane film sheet having a low melting point is heated and pressurized while being closely attached to the PET film sheet having a relatively high melting point so that a phenomenon that the surface of the urethane film sheet is elongated or made nonuniform is prevented and wrinkles or bubbles are not fundamentally generated during fusion.
  • a film sheet-separating process in which the upper and lower PET film sheets 104a and 104b that are not fused in the fusion process are wound around the upper and lower PET winding rollers 123b and 123a and are separated from each other, is performed, and a heating unit-winding process in which, if the upper and lower PET film sheets 104a and 104b are separated in the film sheet-separating process, the upper and lower urethane film sheets 103a and 103b allow the plane-shaped carbon heating unit 105 that is fused on the upper and lower surfaces of the upper and lower urethane film sheets 103a and 103b to be wound around the heating unit winding roller 124, is performed.
  • the PET film sheets 104a and 104b are recovered, and only the coated plane-shaped carbon heating unit 105 is separated and wound.
  • one surface of the upper and lower urethane film sheets 103a and 103b that contact the upper and lower PET film sheets 104a and 104b is coated with an adhesive to be release-paper-processed so that the PET film sheet and the urethane film sheet, which are supplied while overlapping each other, are not pulled and are closely attached to each other.
  • the adhesive is coated on the back side of the PET film sheet so that the PET film sheet is not slid on the roller or is not pulled.
  • the urethane film sheet and the PET film sheet may be completely closely attached to each other.
  • PET film sheets that form a flat and even surface when a plane-shaped carbon heating unit is coated with urethane are supplied while overlapping urethane film sheets and simultaneously, the urethane film sheets are indirectly heated to the temperature less than a melting point due to the PET film sheets so that the surface of the urethane film sheets is maintained in a uniform state even under high temperature heating, is prevented from being elongated, problems such as the occurrence of wrinkles or bubbles caused by a temperature difference between the plane-shaped carbon heating unit and the electrode plate are fundamentally prevented, the urethane film sheets are simultaneously coated on the upper and lower surfaces of the plane-shaped carbon heating unit, a coating time is reduced and productivity is improved.
  • the used PET film sheets can be re-wound around the PET winding roller and can be reused, resources are prevented from being wasted, and since a coating thickness is made uniform by the urethane film sheets fused on the upper and lower surfaces of the plane-shaped carbon heating unit so that the uniformity of the product can be sought.

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  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Surface Heating Bodies (AREA)
  • Resistance Heating (AREA)

Abstract

Provided are a coating apparatus of a plane-shaped carbon heating unit in which urethane film sheets having excellent elasticity are simultaneously coated on upper and lower surfaces of the plane-shaped carbon heating unit with which a copper plate is combined, so that a coating time is reduced, the urethane film sheets are prevented from being pulled due to a time difference between the plane-shaped carbon heating unit and the copper plate, and coating defects caused by bubbles are prevented in advance, and a coating method thereof.

Description

COATING APPARATUS OF PLANE-SHAPED CARBON HEATING UNIT AND COATING METHOD THEREOF
Technical Field
The present invention relates to a coating apparatus of a plane-shaped carbon heating unit and a coating method thereof, and more particularly, to a coating apparatus of a plane-shaped carbon heating unit for coating a urethane film sheet on both sides of the plane-shaped carbon heating unit, and a coating method thereof.
Background Art
Traditionally, plane-shaped heating bodies are heated by resistance of applied power and has been used in various fields such as electrical carpets, bottom materials, and instant cool-water warming devices.
Plane-shaped heating bodies have been developed to solve problems of conventional heating bodies which have a narrow cross-section of an electrothermal wire and a small heating area and in which an electrothermal wire in which heat is not uniformly transmitted is used.
Conventional plane-shaped carbon heating bodies generally comprise a heating unit formed of paper and including a carbon printing layer formed as carbon is printed on its surface, at least two electrode bodies which are formed in a thin plate shape, are provided on the heating unit and transmit (+) and (-) polarities, and an insulating body which is coated on its surface so as to prevent a safety accident such as an electric shock caused by an electric leakage.
Such a plane-shaped carbon heating unit is constituted in such a way that carbon is printed on the surface of a heating unit formed of paper, to form a carbon printing layer, an electrode body is simply arranged on the heating unit, an insulating body is compressed and coating on the surface of the electrode body so that the insulating body compresses the electrode body and the electrode body and the heating unit face each other and are electrically connected. However, in the above-mentioned plane-shaped heating unit, a coated insulating body is easily come off by a stress such as repetitive use and shape deformation, the electrode body is not easily compressed, a clearance is generated between the plane-shaped heating unit and the electrode body and an electrical contact becomes bad and cracks occur in the carbon printing layer of the plane-shaped heating unit having no elasticity and an electrical contact may become bad.
The newly-developed plane-shaped heating unit that has been developed to solve the above-described problems is referred to as a plane-shaped carbon heating unit. Thus, the plane-shaped carbon heating unit is a woven fabric and is dyed with a carbon solution and comprises an electrode body of a thin copper or metal thin plate that is attached to both ends of the plane-shaped heating unit and therebetween using a carbon adhesive and an insulating body for coating the surface of the plane-shaped heating unit to which the electrode body is attached. The electrode bodies are attached to both ends of the plane-shaped heating unit and therebetween using the carbon adhesive. The electrode bodies are electrically connected to an external power source and transmit (+) and (-) polarities to the plane-shaped heating unit and the plane-shaped heating unit is heated by resistance which is an electrical characteristic.
The conventional plane-shaped carbon heating unit coats the surface with urethane so as to prevent a safety accident such as an electric shock caused by an electrical leakage.
When the urethane coating described above is used in mats, mattresses and car sheets, elasticity and an elastic restoration force are excellent, the performance of the heating unit is not degraded and the reliability of a product can be improved.
However, conventional urethane coating with respect to fibers is performed by a process in which a urethane raw material (a urethane ball) is heated and molten in a hoper, urethane of the molten hoper is coated on the surface of a raw cloth transmitted from the lower portion of the hoper and is cooled.
Thus, in prior art, when the plane-shaped carbon heating unit is coated with urethane, a troublesome process in which waste of the urethane raw material caused by coating of the molten urethane is serious and the thickness of a coating layer is not uniform, and after urethane is coated on the upper surface of the plane-shaped carbon heating unit and is cooled after a predetermined amount of time and the lower surface of the plane-shaped carbon heating unit is coated, should be performed. Thus, a coating process is lengthened. In addition, the plane-shaped carbon heating unit is used in places in which there are many contacts and shape deformation. Thus, although the coated urethane and the plane-shaped carbon heating unit must be strongly attached to each other, coating is performed by simple coating and cooling in the coating process and the cooling process. Thus, if the shape of the plane-shaped carbon heating unit is deformed, a problem that the plane-shaped carbon heating unit and the urethane coating layer are come off occurs and the reliability of a product is lowered.
Furthermore, since a plane-shaped carbon heating unit 1 coated by a method of coating urethane, as shown in FIG. 6, is sold or used in units of a predetermined length. Thus, if the coated plane-shaped carbon heating unit 1 is cut by a required length A, a heating unit 1a and an electrode 1 b are exposed from a cut surface S, as shown in FIG. 7 and a problem such as an electric leakage occurs. To solve the above-descried problem, several methods for heating and compressing a urethane film have been suggested. However, if a urethane film sheet is heated at a coating temperature, the urethane film sheet is very easily elongated.
In other words, since the melting point of urethane is 1200C - 14O0C, it is very difficult to heat the urethane film sheet at a high temperature and to compress and coat it.
Accordingly, if the urethane film sheet is coated on the plane-shaped carbon heating unit, due to a difference between the elongated surface area by heating and temperature distribution of the plane-shaped carbon heating unit and the electrode body, the urethane film sheet is pushed out from the surface of the plane-shaped carbon heating unit during coating or bubbles are generated. Thus, a defective rate increases and productivity is seriously lowered so that there are no profits by enforcement and actually, enforcement is not possible.
Disclosure of the Invention
The objective of the present invention is to provide a coating apparatus of a plane-shaped carbon heating unit in which urethane film sheets are heated at a higher temperature than the melting point of urethane, problems that may occur by a temperature difference between the plane-shaped carbon heating unit and an electrode body and a change in surface caused by elongation of the urethane film sheets are solved and the urethane film sheets are simultaneously heated and compressed on upper and lower surfaces of the plane-shaped carbon heating unit, and a coating method thereof. To achieve the above objective, according to an aspect of the present invention, the present invention provides a coating apparatus of a plane-shaped carbon heating unit, the apparatus comprising: upper and lower urethane rollers which are installed to be freely rotated in upper and lower predetermined positions, respectively, of one side of a panel comprised of a plurality of horizontal and vertical frames and in which bobbins around which urethane film sheets each having a predetermined width are wound are respectively inserted and combined; upper and lower PET rollers which are installed to be freely rotated in the upper and lower predetermined positions of one side of the panel and in which bobbins around which PET film sheets each having a predetermined width are wound are respectively inserted and combined; a heating unit of a film sheet which heats a urethane film sheet of the upper urethane roller, a PET film sheet of the upper PET roller, a urethane film sheet of the lower urethane roller, and a PET film sheet of the lower PET roller; a pressure roller which presses the upper and lower urethane film sheets and is rotated so that the upper and lower urethane film sheet that is heated by the heating unit of the film sheet and is conveyed and the plane-shaped carbon heating unit having a predetermined area to be supplied are fused; a cooling roller which allows one of the upper and lower PET film sheets to be closely attached to part of outer surfaces and to be conveyed to the other side so that the urethane film sheet fused together with the plane-shaped carbon heating unit by the pressure roller and the upper and lower PET film sheets are cooled and in which a cooling member is built; and a separating unit of a PET film sheet which separates the upper and lower PET film sheets from the fused urethane film sheets conveyed from the cooling roller.
According to another aspect of the present invention, there is provided a coating apparatus of a plane-shaped carbon heating unit, the apparatus comprising: upper and lower urethane rollers which are installed to be freely rotated in upper and lower predetermined positions, respectively, of one side of a panel comprised of a plurality of horizontal and vertical frames and in which bobbins around which urethane film sheets each having a predetermined width are wound are respectively inserted and combined; upper and lower PET rollers which are installed to be freely rotated in the upper and lower predetermined positions of one side of the panel and in which bobbins around which PET film sheets each having a predetermined width are wound are respectively inserted and combined; a heating unit of a film sheet which heats a urethane film sheet of the upper urethane roller, a PET film sheet of the upper PET roller, a urethane film sheet of the lower urethane roller, and a PET film sheet of the lower PET roller; a heating unit supply roller which is installed to be freely rotated in a predetermined position of one side of the panel to be supplied between the upper and lower urethane film sheets to be supplied by the heating unit and in which a bobbin around which a woven plane-shaped carbon heating unit having a predetermined width is wound is inserted and combined; a pressure roller which presses the upper and lower urethane film sheets and is rotated so that the upper and lower urethane film sheet that is heated by the heating unit of the film sheet and is conveyed and the plane-shaped carbon heating unit having a predetermined area to be supplied are fused; a cooling roller which allows one of the upper and lower PET film sheets to be closely attached to part of outer surfaces and to be conveyed to the other side so that the urethane film sheet fused together with the plane-shaped carbon heating unit by the pressure roller and the upper and lower PET film sheets are cooled and in which a cooling member is built; and a separating unit of a PET film sheet which separates the upper and lower PET film sheets from the fused urethane film sheets conveyed from the cooling roller.
The heating unit of the film sheet may comprise: a first guide roller which is installed in a predetermined position of the panel and guides the urethane film sheet supplied by the lower urethane roller to overlap an upper portion of the PET film sheet supplied by the lower PET roller; a second guide roller which is installed in a predetermined position of the panel and guides the PET film sheet supplied by the upper PET roller to overlap an upper portion of the urethane film sheet supplied by the upper urethane roller; a first heating roller which is installed to be closely attached to the first guide roller in a predetermined position of the panel and in which a heating member that allows the urethane film sheet and the PET film sheet guided by the first guide roller and closely attached to the outer diameter surface of the first heating roller to be heated at a predetermined temperature and conveyed; and a second heating roller which is installed adjacent to the other-side panel of the first heating roller and in which a heating member that allows the urethane film sheet and the PET film sheet guided by the second guide roller and closely attached to the outer diameter surface of the second heating roller to be heated at a predetermined temperature and conveyed.
The heating member may be a heating coil which is built in a drum of the first heating roller or the second heating roller to heat the drum. The cooling member may comprise: a plurality of cooling flow paths which are formed in the drum of the cooling roller; and a cooling water circulating device which is installed distant from the panel so as to supply and discharge the cooling water into the cooling flow paths.
The apparatus may further comprise: a first interlocking sprocket which is installed in at least one end of the first heating roller and the pressure roller; a first driving motor in which a driving sprocket is shaft-inserted so that the first driving motor can be connected to the first interlocking sprocket by a chain and which is installed on the panel to generate power; a second interlocking sprocket which is shaft-inserted in one of shafts of the first heating roller and the pressure roller in which the first interlocking sprocket is shaft-inserted; and a third interlocking sprocket which is installed in one end of the pressure roller and the first heating roller to be connected to the second interlocking sprocket by a chain. The apparatus may further comprise: a rotative bracket which is surrounded on outsides of a shaft so that shafts of both ends of the first guide roller and the second guide roller can be rotated freely; a guide bracket in which a guide groove is formed inside of both-sides of the guide bracket so that both ends of the rotative bracket are inserted in the guide groove and ascend and descend by a predetermined inclination upwards and downwards and in which a screw hole is formed in one of upper and lower ends of the guide bracket; and a lead screw which is combined with the screw hole of the guide bracket so that the lead screw is freely rotated at one of upper and lower ends of the rotative bracket.
The separating unit of the film sheet may comprise: a lower PET winding roller which is installed in a predetermined position of a lower portion of the panel at the other side of the cooling roller so that the PET film sheet under the urethane film sheet cooled by the cooling roller is separated from the urethane film sheet and is wound therearound; an upper PET winding roller which is installed in a predetermined position of an upper portion of the panel at the other side of the cooling roller so that the PET film sheet on the urethane film sheet cooled by the cooling roller is separated from the urethane film sheet and is wound therearound; and a heating unit winding roller which is installed in a predetermined position of the panel at the other side of the cooling roller so that the plane-shaped carbon heating unit in which the upper and lower PET film sheets are separated from each other by the upper and lower PET winding rollers and the urethane film sheet is coated, is wound on the heating unit winding roller.
A power transmission member may be installed at one end of the upper and lower PET winding rollers and the heating unit winding roller, respectively, to be rotated by second, third, and fourth driving motors installed on the panel.
The apparatus may further comprise a compression roller which is installed on the panel to be ascended and descended at a predetermined angle at the outer diameter surface of the other side of the heating roller so that the PET film sheet passing the pressure roller and the second heating roller and the fused urethane film sheet are closely attached to a predetermined region of the outer diameter surface of the pressure roller and is rotated and compress the urethane film sheet. The apparatus may further comprise: a first interlocking gear which is shaft-inserted in one of both ends of the second heating roller; and a second interlocking gear which is shaft-inserted in the pressure roller so as to be meshed with the first interlocking gear.
According to another aspect of the present invention, there is provided a method of coating a plane-shaped carbon heating unit, the method comprising: a paper-combining process in which upper and lower urethane film sheets are closely attached to upper and lower surfaces of a woven plane-shaped carbon heating unit and PET film sheets are closely attached to an upper surface of the upper urethane film sheet and a lower surface of the lower urethane film sheet; a heating process in which some of the upper and lower PET film sheets, the upper and lower urethane film sheets, and the plane-shaped carbon heating unit that are combined in the paper-combining process are surrounded on outsides of a heating roller in which a heating member is built; a fusing process in which the upper and lower PET film sheets, the upper and lower urethane film sheets, and the plane-shaped carbon heating unit that are heated in the heating process are pressed so that the upper and lower urethane film sheets and the plane-shaped carbon heating unit are fused; a cooling process in which some of the upper and lower PET film sheets conveyed in the fusion process and the fused upper and lower urethane film sheets and plane-shaped carbon heating unit are surrounded on outsides of a cooling roller in which a cooling member is built, and is conveyed; a film sheet-separating process in which the upper and lower PET film sheets that are not fused in the fusion process are separated from each other and wound around upper and lower PET winding rollers; and a heating unit-winding process in which the upper and lower PET film sheets are separated from each other in the film sheet-separating process and the urethane film sheets and the fused plane-shaped carbon heating unit are wound.
In the paper-combining process, one surface of the upper and lower urethane film sheets that contact the upper and lower PET film sheets may be coated with an adhesive to be release-paper-processed. Brief Description of the Drawings
FIG. 1 illustrates a coating apparatus of a plane-shaped carbon heating unit according to an embodiment of the present invention. FIG. 2 illustrates a coating apparatus of a plane-shaped carbon heating unit according to another embodiment of the present invention.
FIG. 3 illustrates the state where the plane-shaped carbon heating unit according to the present invention is coated with urethane.
FIG. 4 illustrates a guide bracket and a rotation bracket according to the present invention.
FIG. 5 illustrates a roll of the plane-shaped carbon heating unit to which a copper plate is combined.
FIG. 6 illustrates the state where a conventional plane-shaped carbon heating unit is coated with urethane. FIG. 7 illustrates the state where the conventional coated plane-shaped carbon heating unit is cut.
Best mode for carrying out the Invention
A coating apparatus of a plane-shaped carbon heating unit and a coating method thereof according to the present invention will now be described with reference to FIGS. 1 through 5.
First, a panel for constituting a coating apparatus of a plane-shaped carbon heating unit according to an embodiment of the present invention are assembled using a plurality of general horizontal and vertical frames and are not limited to its shape and structure. However, the panel for constituting a coating apparatus of a plane-shaped carbon heating unit may be installed to rotate freely in a predetermined position in the state where bearings are surrounded on outsides of shafts of upper and lower urethane rollers 101a and 101 b, upper and lower PET rollers 102a and 102b, a first heating roller 111 , a second heating roller 112, a pressure roller 106, a first guide roller 109, a second guide roller 1 10, and a compression roller 125.
Thus, hereinafter, when the construction for the coating apparatus of the plane-shaped carbon heating unit according to the present invention is described with reference to the attached drawings, explanation for the panel and drawing reference will be omitted.
First, FIGS. 1 and 2 schematically illustrate the coating apparatus of the plane-shaped carbon heating unit according to first and second embodiments of the present invention. A difference in constructions between the first and second embodiments of the present invention is that, in the second embodiment, a heating unit supply roller 108 is added to the construction of the first embodiment, in the first embodiment, the plane-shaped carbon heating unit 105 having a predetermined length is supplied by a unit length and in the second embodiment, the plane-shaped carbon heating unit 105 is wound around a bobbin and is continuously supplied.
Here, the plane-shaped carbon heating unit 105 may be woven and comprises a plane-shaped carbon heating unit in which an electrode plate 105a is attached to one of both ends of the plane-shaped carbon heating unit 105 and a plane-shaped carbon heating unit in which the electrode plate 105a is not attached to any one of both ends of the plane-shaped carbon heating unit 105.
The specific construction and operation will now be described according to the first and second embodiments of the present invention, respectively, and the construction of the second embodiment is considered to be described through description of the construction of the first embodiment, and only additional parts of additional construction and operation of the heating unit supply roller 108 added in the second embodiment will be described separately. - First embodiment -
As illustrated in FIG. 1 , upper and lower urethane rollers 101a and 101 b are installed at one-side upper and lower portions of a panel so that a bobbin around which a urethane film sheet to be closely coated (fused) on upper and lower surfaces of the plane-shaped carbon heating unit is wound can be mounted on the upper and lower urethane rollers 101a and 101 b.
Here, bearings are generally surrounded on outsides of shafts of both ends of rollers according to the present invention, and the bearings are installed on a panel so that rotation of the rollers can be easily performed, as well known. Thus, a detailed description thereof will be omitted.
Upper and lower PET rollers 102a and 102b are installed in a position that is separated from the upper and lower urethane rollers 101a and 101 b by a predetermined distance, respectively. Thus, bobbins around which PET film sheets 104a and 104b are wound are inserted and installed in the upper and lower PET rollers 102a and 102b, respectively.
Urethane film sheets 103a and 103b and PET film sheets 104a and 104b of the upper and lower urethane rollers 101a and 101 b and the upper and lower PET rollers 102a and 102b are heated and compressed respectively or simultaneously by first and second heating rollers 111 and 112 in which heating elements are built, as shown in FIG. 1. Thus, the urethane film sheet 103b of the lower urethane roller 101 b and the PET film sheet 104b of the lower PET roller 102b are heated by the first heating roller 111 , and the urethane film sheet 103a of the upper urethane roller 101a and the PET film sheet 104a of the upper PET roller 102a are heated by the second heating roller 112.
Here, the heating elements may be heating coils (electrothermal wires)(not shown) which are built in drums of the first heating roller 111 and the second heating roller 112 to heat the drums (outer diameter surfaces) or burners. The heating elements built in the drums are well known. The present invention is not limited to the above-described heating coils but may constitute the first and second heating rollers 111 and 112 by adopting various methods. Thus, the first heating roller 111 is installed in a predetermined position between the upper and lower urethane rollers 101a and 101b and between the upper and lower PET rollers 102a and 102b, and the second heating roller 112 is installed adjacent to the first heating roller 111. A first guide roller 109 is installed to be closely attached to the outer diameter surface of the first heating roller 111 so that the urethane film sheet 103b of the lower urethane roller 101 b and the PET film sheet 104b of the lower PET roller 102b are guided to the first guide roller 109 and is rotated and conveyed along the outer diameter surface of the first heating roller 111.
In other words, the first guide roller 109 is closely attached to the outer diameter surface of the first heating roller 111 in a lower predetermined position of the first heating roller 111 , and the urethane film sheet 103b and the PET film sheet 104b guided to the first guide roller 109 are wound in a predetermined region of the outer diameter surface of the first heating roller 111 and is rotated and conveyed upwards so that thermal conductivity is increased and the urethane film sheet 103b is sufficiently heated by the first heating roller 111.
The second heating roller 112 installed to be adjacent to the first heating roller 111 is installed at the adjacent other side, as shown in FIG. 1. Thus, a second guide roller 110 is installed so that, as the urethane film sheet 103b of the lower urethane roller 10b and the PET film sheet 104b of the lower PET roller 102b are guided to the first guide roller 109 installed to be closely attached to the first heating roller 111 , they are closely attached to the second heating roller 112. Thus, the second heating roller 112 allows the urethane film sheet 103a of the upper urethane roller 101a and the PET film sheet 104a of the upper PET roller 102a are guided to the second guide roller 110 and are wound in a predetermined region of the outer diameter surface of the second heating roller 112 and are rotated and conveyed downwards. Here, the PET film sheets 104a and 104b of the upper and lower
PET rollers 102a and 102b are directly closely attached to the outer diameter surfaces of the second heating roller 112 and the first heating roller 111 and can be directly heated by the second heating roller 112 and the first heating roller 111. They are guided to the second guide roller 110 and the first guide roller 109, and the urethane film sheets 103a and 103b of the upper and lower urethane rollers 101a and 101 b overlap the PET film sheets 104a and 104b and are indirectly closely attached to the outer diameter surfaces of the second heating roller 112 and the first heating roller 111 , are guided to the second guide roller 110 and the first guide roller 109 and are indirectly heated by the second heating roller 112 and the first heating roller 111.
In other words, the first heating roller 111 allows the urethane film sheet 103b to be rotated and conveyed upwards, and the second heating roller 112 allows the urethane film sheet 103b to be rotated and conveyed downwards. Thus, when the urethane film sheets 103a and 103b heated by the first heating roller 111 and the second heating roller 112 are combined with each other, the upper and lower urethane film sheets 103a and 103b are disposed in the center of the combined paper, and the PET film sheets 104a and 104b are disposed on and below the upper and lower urethane film sheets 103a and 103b.
The upper urethane film sheet 103a and the upper PET film sheet 104a which allow a pressure roller 106 to be closely installed to the lower portion of the second heating roller 112, are heated by the second heating roller 112 and are rotated and conveyed downwards, the lower urethane film sheet 103b and the upper and lower PET film sheets 104a and 104b which are heated by the first heating roller 111 , are rotated and conveyed upwards and are conveyed to the second heating roller 112, pass between the pressure roller 106 and the second heating roller 112 and are pressurized and fused, as shown in FIG. 1.
Here, the plane-shaped carbon heating unit 105 which is cut by a unit length is supplied and seated by a predetermined supply unit at the upper surface of the urethane film sheet 103b which is heated and conveyed by the first heating roller 111 , as shown in FIG. 1 , so that the heated lower urethane film sheet 103b and the plane-shaped carbon heating unit 105 can be together conveyed and the plane-shaped carbon heating unit 105 can be disposed between the heated lower urethane film sheet 103b and the heated upper urethane film sheet 103a which is heated by the second heating roller 112.
The present invention is not limited to the above-described supply unit and a user may put the plane-shaped carbon heating unit 105 cut by a predetermined length on the upper surface of the lower urethane film sheet 103b which is conveyed from the second heating roller 112.
Thus, the plane-shaped carbon heating unit 105 is disposed between the upper and lower urethane film sheets 103a and 103b which pass between the second heating roller 112 and the pressure roller 106 so that the plane-shaped carbon heating unit 105 can be coated by the upper and lower urethane film sheets 103a and 103b.
In particular, the compression roller 125 is closely attached to a predetermined position of an outer diameter surface of the other side of the pressure roller 106, as shown in FIG. 1. As a result, the urethane film sheets which are fused by heating and compression by the second heating roller 112 and the pressure roller 106 may be wound around a predetermined region of the pressure roller 106 and may be rotated and conveyed to improve a fusion rate.
As described above, the urethane film sheets according to the present invention are heated by the first heating roller 111 and the second heating roller 112 and are heated and compressed by the second heating roller 1 12, the pressure roller 106, and the compression roller 125 so that the upper and lower urethane film sheets 103a and 103b can be fused.
The melting point of a traditional urethane film sheet (polyurethane) is 14O0C . In general, the urethane film sheet (polyurethane) is heated by a heating roller to over 1400C , as mentioned in the prior art, the urethane film sheet is elongated and its surfaces becomes irregularly uneven. Thus, even when it is compressed by the pressure roller 106 and the compression roller 125, bubbles enter the fused surface or it is pulled and wrinkles are generated.
However, according to the present invention, when the urethane film sheets are heated, PET film sheets having a melting point of 225°C-265°C are directly heated by the first heating roller 1 1 1 and the second heating roller 1 12 to a proper temperature in which the PET film sheet is not elongated. As a result, the urethane film sheets 103a and 103b which are conveyed while overlapping the PET film sheets 104a and 104b are indirectly heated to a high temperature near to 140 °C . At this time, since the urethane film sheets 103a and 103b which are heated to a high temperature overlap the PET film sheets 104a and 104b which are just heated and have no surface change, its surface elongation is prevented and its original form during supply is maintained and the urethane film sheets 103a and 103b can be conveyed together with the PET film sheets 104a and 104b.
Thus, even when the upper and lower urethane film sheets 103a and 103b are pressurized while passing the second heating roller 1 12, the pressure roller 106, and the compression roller 125, they contact each other and are fused while their surfaces are even. Thus, wrinkles are not generated on the fused surface and bubbles are not generated between the upper and lower urethane film sheets 103a and 103b. In particular, since the urethane film sheets 103a and 113b and the PET film sheets 104a and 104b are heated at a high temperature, a minor temperature difference between the plane-shaped carbon heating unit 105 and the electrode plate 105a attached thereto does not affect conditions for fusing the upper and lower urethane film sheets 103a and 103b so that problems caused by a fusion rate or a coating defective rate due to the temperature difference can be completely solved.
On the other hand, the upper and lower PET film sheets 104a and 104b, which pass the first and second heating rollers 111 and 112 and the pressure roller 106 and the compression roller 125, respectively, are not heated by the first and second heating rollers 111 and 112 up to the melting point of the PET film sheet. Thus, even when the upper and lower urethane film sheets 103a and 103b are fused, the PET film sheets 104a and 104b are not fused on the upper and lower urethane film sheets 103a and 103b and are maintained while only overlapping each other. As described above, the urethane film sheet which is fused by the pressure roller 106 and the compression roller 125, and the upper and lower PET film sheets 104a and 104b which are conveyed while overlapping upper and lower surfaces of the urethane film sheet, are installed adjacent to the pressure roller 106 and the compression roller 125, some of them are surrounded on outsides of a cooling roller 107 in which a cooling member is built and are rotated and conveyed, and as such, they are cooled.
Here, the cooling member is installed on the panel or distant from the panel. The cooling member may comprise a cooling water circulating device (not shown) having a pump for conveying a cooling water forcibly and a supply pipe for conveying the cooling water to the cooling roller 107 and a plurality of cooling flow paths (not shown) which are formed inside a drum of the cooling roller 107. The above-described cooling member may also be used by adopting a well-known technology, like the heating member, and the present invention is not limited to this and may adopt and change various technologies. The upper and lower PET film sheets 104a and 104b which are cooled by the cooling roller 107, the upper and lower urethane film sheets 103a and 103b which are fused therebetween, and the plane-shaped carbon heating unit 105 are separated by upper and lower PET winding rollers 123b and 123a and a heating unit winding roller 124 from one another. Thus, the upper and lower PET winding rollers 123b and 123a may be installed to be spaced apart from the other side of the cooling roller 107 by a predetermined distance so that minor heat generated in the PET film sheet and the urethane film sheet passing the cooling roller 107 can be completely cooled at a room temperature.
Thus, the conveyed upper and lower PET film sheets 104a and 104b are separated from each other and wound around the upper and lower PET winding rollers 123b and 123a, and after the upper and lower PET film sheets 104a and 104b are separated from each other, the plane-shaped carbon heating unit 105 which is coated with the urethane film sheets 103a and 103b is guided to the heating unit winding roller 124 and is wound therearound.
Preferably, a power transmission member (a pulley or a sprocket that can be combined with a belt or a chain) is installed at one end of the upper and lower PET winding rollers 123b and 123a and the heating unit winding roller 124 and can be rotated by second, third, and fourth driving motors (not shown) installed on the panel so that the urethane film sheets 103a and 103b of the upper and lower urethane rollers 101a and 101b and the PET film sheets 104a and 104b of the upper and lower PET rollers 102a and 102b can be conveyed in other direction according to a coating process.
More preferably, a first interlocking sprocket 113 is shaft-inserted in at least one end of the first heating roller 111 and the pressure roller 106, and a driving sprocket 114 is shaft-inserted in a first driving motor 115 that is installed on the panel and generates power, to be connected to the first interlocking sprocket 113 by a chain. The first heating roller 111 or the pressure roller 106 is rotated by the first driving motor 115, and a second interlocking sprocket 116 and a third interlocking sprocket 117 are shaft-inserted in the first heating roller 111 and the pressure roller 106, respectively, so that the first heating roller 111 and the pressure roller 106 can be interlocked with each other and then the second interlocking sprocket 116 and the third interlocking sprocket 117 can be connected to each other by a chain so that all of the first heating roller 111 and the pressure roller 106 can be rotated by the first driving motor 115. In other words, a rotative force of the first driving motor 115 may be transmitted to the pressure roller 106, and the rotative force transmitted to the pressure roller 106 may be transmitted to the first heating roller 111.
Furthermore, a first interlocking gear (not shown) is shaft-inserted in one of both ends of the second heating roller 112, and a second interlocking gear (not shown) is shaft-inserted in the pressure roller 106 to be meshed with the first interlocking gear so that the first heating roller 111 , the second heating roller 112, and the pressure roller 106 can heat, press, and convey the upper and lower urethane film sheets 103a and 103b, the upper and lower PET film sheets 104a and 104b, and the plane-shaped carbon heating unit 105 using the first driving motor 115 at the same rotation speed.
The first guide roller 109, the second guide roller 110, and the compression roller 125 are installed on the panel to be closely attached to outer diameter surfaces of the first heating roller 111 , the second heating roller 112, and the pressure roller 106, respectively. Thus, the first guide roller 109, the second guide roller 110, and the compression roller 125, which are closely attached to the outer diameter surfaces of the first heating roller 111 , the second heating roller 112, and the pressure roller 106, are spaced apart from one another by a predetermined distance so that the upper and lower urethane film sheets 103a and 103b and the upper and lower PET film sheets 104a and 104b can be connected to respective rollers installed on the panel. As such, preparation for work for passing film sheets therebetween can proceed smoothly. Thus, a rotative bracket 118 is surrounded on outsides of a shaft and is installed at the shaft so that shafts of the first guide roller 109, the second guide roller 110, and the compression roller 125 can be rotated freely, and the rotative bracket 118 comprises a bearing that is surrounded on outsides of the shaft and is installed at the shaft. A guide groove 119 is formed at inner both sides of a guide bracket 121 , which is installed on the panel and ascends and descends the rotative bracket 118 in a vertical direction or in a slant line direction, as shown in FIGS. 1 and 4, so that both ends of the rotative bracket 118 are inserted in the guide groove 119 and guided thereto. A screw hole 120 is formed in one of upper and lower ends of the guide bracket 121 , and a lead screw 122 is combined with the screw hole 120 so as to be connected to the screw hole 120 and to be freely rotated at one of upper and lower ends of the rotative bracket 118.
Thus, when the lead screw 122 is rotated, the lead screw 122 ascends and descends along the screw hole 120, and the rotative bracket 118 is ascended and descended together so that the first guide roller 109, the second guide roller 110, and the compression roller 125 can be spaced apart from or be closely attached to the first heating roller 111 , the second heating roller 112, and the pressure roller 106, respectively.
- Second embodiment -
A second embodiment of the present invention is the same as the first embodiment of the present invention with respect to the structure and operation. However, as shown in FIG. 2, the heating unit supply roller 108 is installed at one side of the panel so that the roll-shaped and plane-shaped carbon heating unit 105 shown in FIG. 5 can be continuously supplied between the upper and lower urethane film sheets 103a and 103b. As such, a bobbin around which the plane-shaped carbon heating unit 105 having a predetermined width is wound is inserted in and combined with the heating unit supply roller 108. The plane-shaped carbon heating unit 105 can be supplied between the first heating roller 1 11 and the second heating roller 1 12 directly from the heating unit supply roller 108.
A difference between the first and second embodiments of the present invention is that, as the plane-shaped carbon heating unit 105 that is cut by a unit length if necessary is supplied between the upper and lower urethane film sheets 103a and 103b at regular intervals, all outer edges of the plane-shaped carbon heating unit 105 can be coating with a urethane film sheet 103c, as shown in FIG. 3.
Thus, when the heating unit that is continuously coated with urethane is cut by a predetermined length, a cut surface is exposed, as shown in FIG. 7, so that problems such as a safety accident and the stability of a product can be fundamentally solved.
A method of coating the plane-shaped carbon heating unit 105 according to an embodiment of the present invention will now be described.
First, the plane-shaped carbon heating unit 105 is continuously supplied by the heating unit supply roller 108 shown in FIG. 2 or the plane-shaped carbon heating unit 105 is supplied by a predetermined supply unit at predetermined intervals. At this time, a paper-combining process in which the urethane film sheets 103a and 103b of the upper and lower urethane rollers 101a and 101 b and the PET film sheets 104a and 104b of the upper and lower PET rollers 102a and 102b are supplied and conveyed so as to be closely attached to upper and lower portions of the plane-shaped carbon heating unit 105, is performed. In this case, a heating process in which the upper and lower PET film sheets 104a and 104b, some of the upper and lower urethane film sheets 103a and 103b, and the plane-shaped carbon heating unit 105, which are combined with one another in the paper-combining process, are surrounded on outsides of the heating rollers 111 and 112 in which heating members are built, and are conveyed, is performed. In the heating process, the upper urethane film sheet 103a is closely attached to the upper portion of the upper PET film sheet 104a, and the lower urethane film sheet 103b is closely attached to the upper portion of the lower PET film sheet 104b. In this case, the guide rollers 109 and 110 are installed to be closely attached to the outer diameter surfaces of the heating rollers 111 and 112 so that the urethane film sheets 103a and 103b can be indirectly heated.
Thus, a fusing process in which, after the upper and lower PET film sheets 104a and 104b, the upper and lower urethane film sheets 103a and 103b, and the plane-shaped carbon heating unit 105, which are heated in the heating process, pass a pair of pressure rollers 106 to be pressurized or one of the heating rollers 111 and 112 and the pressure roller 106 are closely attached to one another, the upper and lower urethane film sheets 103a and 103b which are heated by passing therebetween and the plane-shaped carbon heating unit 105 disposed therebetween are fused, is performed.
In this case, as described above, the urethane film sheet having a low melting point is heated and pressurized while being closely attached to the PET film sheet having a relatively high melting point so that a phenomenon that the surface of the urethane film sheet is elongated or made nonuniform is prevented and wrinkles or bubbles are not fundamentally generated during fusion.
Next, a cooling process in which some of the upper and lower PET film sheets 104a and 104b conveyed in the fusion process and the fused upper and lower urethane film sheets 103a and 103b and plane-shaped carbon heating unit 105 are surrounded on outsides of the cooling roller 107 in which cooling members are built, and are conveyed so that the upper and lower PET film sheets 104a and 104b and the fused upper and lower urethane film sheets 103a and 103b and plane-shaped carbon heating unit 105 are cooled, is performed.
Furthermore, a film sheet-separating process in which the upper and lower PET film sheets 104a and 104b that are not fused in the fusion process are wound around the upper and lower PET winding rollers 123b and 123a and are separated from each other, is performed, and a heating unit-winding process in which, if the upper and lower PET film sheets 104a and 104b are separated in the film sheet-separating process, the upper and lower urethane film sheets 103a and 103b allow the plane-shaped carbon heating unit 105 that is fused on the upper and lower surfaces of the upper and lower urethane film sheets 103a and 103b to be wound around the heating unit winding roller 124, is performed. As such, the PET film sheets 104a and 104b are recovered, and only the coated plane-shaped carbon heating unit 105 is separated and wound.
Here, one surface of the upper and lower urethane film sheets 103a and 103b that contact the upper and lower PET film sheets 104a and 104b is coated with an adhesive to be release-paper-processed so that the PET film sheet and the urethane film sheet, which are supplied while overlapping each other, are not pulled and are closely attached to each other. As occasion demands, the adhesive is coated on the back side of the PET film sheet so that the PET film sheet is not slid on the roller or is not pulled. Thus, the urethane film sheet and the PET film sheet may be completely closely attached to each other.
The exemplary embodiments having been described in detail, many variations and modifications will become apparent to those skilled in the art. Accordingly, it is intended that the invention not be limited to the specific illustrative embodiments but be interpreted within the full spirit and scope of the appended claims. Industrial Applicability
According to the present invention, PET film sheets that form a flat and even surface when a plane-shaped carbon heating unit is coated with urethane, are supplied while overlapping urethane film sheets and simultaneously, the urethane film sheets are indirectly heated to the temperature less than a melting point due to the PET film sheets so that the surface of the urethane film sheets is maintained in a uniform state even under high temperature heating, is prevented from being elongated, problems such as the occurrence of wrinkles or bubbles caused by a temperature difference between the plane-shaped carbon heating unit and the electrode plate are fundamentally prevented, the urethane film sheets are simultaneously coated on the upper and lower surfaces of the plane-shaped carbon heating unit, a coating time is reduced and productivity is improved. In particular, since when the plane-shaped carbon heating unit cut by a unit length is supplied to be spaced apart from the urethane film sheets by a predetermined distance, all outer edges of the plane-shaped carbon heating unit having the unit length are coated with the urethane film sheets, problems such as electric leakage and short circuit caused by the exposed cut surface can be fundamentally solved, the stability of a product can be sought and its competitiveness can be increased.
Since the used PET film sheets can be re-wound around the PET winding roller and can be reused, resources are prevented from being wasted, and since a coating thickness is made uniform by the urethane film sheets fused on the upper and lower surfaces of the plane-shaped carbon heating unit so that the uniformity of the product can be sought.

Claims

What is claimed is:
1. A coating apparatus of a plane-shaped carbon heating unit, the apparatus comprising: upper and lower urethane rollers which are installed to be freely rotated in upper and lower predetermined positions, respectively, of one side of a panel comprised of a plurality of horizontal and vertical frames and in which bobbins around which urethane film sheets each having a predetermined width are wound are respectively inserted and combined; upper and lower PET rollers which are installed to be freely rotated in the upper and lower predetermined positions of one side of the panel and in which bobbins around which PET film sheets each having a predetermined width are wound are respectively inserted and combined; a heating unit of a film sheet which heats a urethane film sheet of the upper urethane roller, a PET film sheet of the upper PET roller, a urethane film sheet of the lower urethane roller, and a PET film sheet of the lower PET roller; a pressure roller which presses the upper and lower urethane film sheets and is rotated so that the upper and lower urethane film sheet that is heated by the heating unit of the film sheet and is conveyed and the plane-shaped carbon heating unit having a predetermined area to be supplied are fused; a cooling roller which allows one of the upper and lower PET film sheets to be closely attached to part of outer surfaces and to be conveyed to the other side so that the urethane film sheet fused together with the plane-shaped carbon heating unit by the pressure roller and the upper and lower PET film sheets are cooled and in which a cooling member is built; and a separating unit of a PET film sheet which separates the upper and lower PET film sheets from the fused urethane film sheets conveyed from the cooling roller.
2. A coating apparatus of a plane-shaped carbon heating unit, the apparatus comprising: upper and lower urethane rollers which are installed to be freely rotated in upper and lower predetermined positions, respectively, of one side of a panel comprised of a plurality of horizontal and vertical frames and in which bobbins around which urethane film sheets each having a predetermined width are wound are respectively inserted and combined; upper and lower PET rollers which are installed to be freely rotated in the upper and lower predetermined positions of one side of the panel and in which bobbins around which PET film sheets each having a predetermined width are wound are respectively inserted and combined; a heating unit of a film sheet which heats a urethane film sheet of the upper urethane roller, a PET film sheet of the upper PET roller, a urethane film sheet of the lower urethane roller, and a PET film sheet of the lower PET roller; a heating unit supply roller which is installed to be freely rotated in a predetermined position of one side of the panel to be supplied between the upper and lower urethane film sheets to be supplied by the heating unit and in which a bobbin around which a woven plane-shaped carbon heating unit having a predetermined width is wound is inserted and combined; a pressure roller which presses the upper and lower urethane film sheets and is rotated so that the upper and lower urethane film sheet that is heated by the heating unit of the film sheet and is conveyed and the plane-shaped carbon heating unit having a predetermined area to be supplied are fused; a cooling roller which allows one of the upper and lower PET film sheets to be closely attached to part of outer surfaces and to be conveyed to the other side so that the urethane film sheet fused together with the plane-shaped carbon heating unit by the pressure roller and the upper and lower PET film sheets are cooled and in which a cooling member is built; and a separating unit of a PET film sheet which separates the upper and lower PET film sheets from the fused urethane film sheets conveyed from the cooling roller.
3. The apparatus of claim 1 or 2, wherein the heating unit of the film sheet comprises: a first guide roller which is installed in a predetermined position of the panel and guides the urethane film sheet supplied by the lower urethane roller to overlap an upper portion of the PET film sheet supplied by the lower PET roller; a second guide roller which is installed in a predetermined position of the panel and guides the PET film sheet supplied by the upper PET roller to overlap an upper portion of the urethane film sheet supplied by the upper urethane roller; a first heating roller which is installed to be closely attached to the first guide roller in a predetermined position of the panel and in which a heating member that allows the urethane film sheet and the PET film sheet guided by the first guide roller and closely attached to the outer diameter surface of the first heating roller to be heated at a predetermined temperature and conveyed; and a second heating roller which is installed adjacent to the other-side panel of the first heating roller and in which a heating member that allows the urethane film sheet and the PET film sheet guided by the second guide roller and closely attached to the outer diameter surface of the second heating roller to be heated at a predetermined temperature and conveyed.
4. The apparatus of claim 3, wherein the heating member is a heating coil which is built in a drum of the first heating roller or the second heating roller to heat the drum.
5. The apparatus of claim 3, wherein the cooling member comprises: a plurality of cooling flow paths which are formed in the drum of the cooling roller; and a cooling water circulating device which is installed distant from the panel so as to supply and discharge the cooling water into the cooling flow paths.
6. The apparatus of claim 3, further comprising: a first interlocking sprocket which is installed in at least one end of the first heating roller and the pressure roller; a first driving motor in which a driving sprocket is shaft-inserted so that the first driving motor can be connected to the first interlocking sprocket by a chain and which is installed on the panel to generate power; a second interlocking sprocket which is shaft-inserted in one of shafts of the first heating roller and the pressure roller in which the first interlocking sprocket is shaft-inserted; and a third interlocking sprocket which is installed in one end of the pressure roller and the first heating roller to be connected to the second interlocking sprocket by a chain.
7. The apparatus of claim 3, further comprising: a rotative bracket which is surrounded on outsides of a shaft so that shafts of both ends of the first guide roller and the second guide roller can be rotated freely; a guide bracket in which a guide groove is formed inside of both-sides of the guide bracket so that both ends of the rotative bracket are inserted in the guide groove and ascend and descend by a predetermined inclination upwards and downwards and in which a screw hole is formed in one of upper and lower ends of the guide bracket; and a lead screw which is combined with the screw hole of the guide bracket so that the lead screw is freely rotated at one of upper and lower ends of the rotative bracket.
8. The apparatus of claim 1 or 2, wherein the separating unit of the film sheet comprises: a lower PET winding roller which is installed in a predetermined position of a lower portion of the panel at the other side of the cooling roller so that the PET film sheet under the urethane film sheet cooled by the cooling roller is separated from the urethane film sheet and is wound therearound; an upper PET winding roller which is installed in a predetermined position of an upper portion of the panel at the other side of the cooling roller so that the PET film sheet on the urethane film sheet cooled by the cooling roller is separated from the urethane film sheet and is wound therearound; and a heating unit winding roller which is installed in a predetermined position of the panel at the other side of the cooling roller so that the plane-shaped carbon heating unit in which the upper and lower PET film sheets are separated from each other by the upper and lower PET winding rollers and the urethane film sheet is coated, is wound on the heating unit winding roller.
9. The apparatus of claim 8, wherein a power transmission member is installed at one end of the upper and lower PET winding rollers and the heating unit winding roller, respectively, to be rotated by second, third, and fourth driving motors installed on the panel.
10. The apparatus of claim 1 or 2, further comprising a compression roller which is installed on the panel to be ascended and descended at a predetermined angle at the outer diameter surface of the other side of the heating roller so that the PET film sheet passing the pressure roller and the second heating roller and the fused urethane film sheet are closely attached to a predetermined region of the outer diameter surface of the pressure roller and is rotated and compress the urethane film sheet.
11. The apparatus of claim 1 or 2, further comprising: a first interlocking gear which is shaft-inserted in one of both ends of the second heating roller; and a second interlocking gear which is shaft-inserted in the pressure roller so as to be meshed with the first interlocking gear.
12. A method of coating a plane-shaped carbon heating unit, the method comprising: a paper-combining process in which upper and lower urethane film sheets are closely attached to upper and lower surfaces of a woven plane-shaped carbon heating unit and PET film sheets are closely attached to an upper surface of the upper urethane film sheet and a lower surface of the lower urethane film sheet; a heating process in which some of the upper and lower PET film sheets, the upper and lower urethane film sheets, and the plane-shaped carbon heating unit that are combined in the paper-combining process are surrounded on outsides of a heating roller in which a heating member is built; a fusing process in which the upper and lower PET film sheets, the upper and lower urethane film sheets, and the plane-shaped carbon heating unit that are heated in the heating process are pressed so that the upper and lower urethane film sheets and the plane-shaped carbon heating unit are fused; a cooling process in which some of the upper and lower PET film sheets conveyed in the fusion process and the fused upper and lower urethane film sheets and plane-shaped carbon heating unit are surrounded on outsides of a cooling roller in which a cooling member is built, and is conveyed; a film sheet-separating process in which the upper and lower PET film sheets that are not fused in the fusion process are separated from each other and wound around upper and lower PET winding rollers; and a heating unit-winding process in which the upper and lower PET film sheets are separated from each other in the film sheet-separating process and the urethane film sheets and the fused plane-shaped carbon heating unit are wound.
13. The method of claim 12, wherein, in the paper-combining process, one surface of the upper and lower urethane film sheets that contact the upper and lower PET film sheets is coated with an adhesive to be release-paper-processed.
PCT/KR2007/001916 2006-10-04 2007-04-19 Coating apparatus of plane-shaped carbon heating unit and coating method thereof WO2008041790A1 (en)

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