PTC RESISTOR

• US 20100038357A1
• Filed: 01/22/2008
• Published: 02/18/2010
• Est. Priority Date: 01/22/2007
• Status: Abandoned Application

• Current Assignee: Panasonic Intellectual Property Management Co., Ltd. (Panasonic Holdings Corporation)
• Original Assignee: Panasonic Corporation (Panasonic Holdings Corporation)
• Inventors: Ishii, Takahito, Fukuda, Hirosi, Umeda, Akihiro, Uno, Katsuhiko, Nakajima, Keizo
• Application Number:
  US12/521,820
• Publication Number:
  US 20100038357A1
• Time in Patent Office: Days
• US Class Current: 219/553
• CPC Class Codes: H01C 7/021 formed as one or more layers or coatings
• CPC Class Codes: H01C 7/027 consisting of conducting or semi-conducting material dispersed in a non-conductive organic material
• CPC Class Codes: H05B 2203/005 using multiple resistive elements or resistive zones isolated from each other
• CPC Class Codes: H05B 2203/006 using interdigitated electrodes
• CPC Class Codes: H05B 2203/011 Heaters using laterally extending conductive material as connecting means
• CPC Class Codes: H05B 2203/013 Heaters using resistive films or coatings
• CPC Class Codes: H05B 2203/017 Manufacturing methods or apparatus for heaters
• CPC Class Codes: H05B 2203/026 Heaters specially adapted for floor heating
• CPC Class Codes: H05B 2203/029 Heaters specially adapted for seat warmers
• CPC Class Codes: H05B 2214/04 Heating means manufactured by using nanotechnology
• CPC Class Codes: H05B 3/03 Electrodes
• CPC Class Codes: H05B 3/146 Conductive polymers, e.g. polyethylene, thermoplastics
• CPC Class Codes: H05B 3/20 Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater H05B3/62, H05B3/68, H05B3/78, H05B3/84 take precedence
• CPC Class Codes: H05B 3/34 flexible, e.g. heating nets or webs

Abstract

A PTC resistor according to the present invention comprises at least one PTC composition which comprises at least one resin and at least two conductive materials. The at least two conductive materials comprises at least two conductive materials different from each other. The at least one PTC composition may comprise a first PTC composition which comprises a first resin and at least one first conductive material and a second PTC composition which is compounded with the first PTC composition and comprises a second resin and at least one second conductive material. The at least one first conductive material is at least partially different from the at least one second conductive material. One of the first resin and the second resin may comprise a reactant resin and a reactive resin which is cross-linked with the reactant resin. The PTC resistor may comprise a flame retardant agent. The PTC resistor may comprise a liquid-resistant resin.

Claims

1. A PTC resistor comprising:

at least one PTC composition comprising at least one resin and at least two conductive materials, wherein the at least two conductive materials comprises at least two conductive materials different from each other.

2. A PTC resistor according to claim 1, wherein the at least one PTC composition comprises:

a first PTC composition comprising a first resin and at least one first conductive material; and

a second PTC composition compounded with the first PTC composition and comprising a second resin and at least one second conductive material,

wherein the at least one first conductive material is at least partially different from the at least one second conductive material.

3. A PTC resistor according to claim 2, wherein one of the first and second PTC compositions forms clusters which are distributed within the other of the first and second PTC compositions.

4. A PTC resistor according to claim 2, wherein one of the first and second PTC compositions is contained in the PTC resistor at a content of 20-80 wt. %.

5. A PTC resistor according to claim 2, wherein said one of the first and second PTC compositions is contained in the PTC resistor at a content of 30-70 wt. %.

6. A PTC resistor according to claim 2, wherein said one of the first and second PTC compositions is contained in the PTC resistor at a content of 40-60 wt. %.

7. A PTC resistor according to claim 2, wherein one of the first resin and the second resin comprises a reactant resin and a reactive resin which is cross-linked with the reactant resin.

8. A PTC resistor according to claim 7, wherein the reactant resin comprises a modified olefinic resin.

9. A PTC resistor according to claim 8, wherein the modified olefinic resin comprises ester-type ethylene copolymer.

10. A PTC resistor according to claim 9, wherein the ester-type ethylene copolymer comprises any one of ethylene/vinyl acetate copolymer, ethylene/ethyl acrylate copolymer, ethylene/methyl methacrylate copolymer, ethylene/methacrylic acid copolymer, and ethylene/butyl acrylate copolymer.

11. A PTC resistor according to claim 7, wherein the reactive resin is contained at a content of 1-20 wt. % in said one of the first resin and the second resin.

12. A PTC resistor according to claim 7, wherein the reactive resin is contained at a content of 1-10 wt. % in said one of the first resin and the second resin.

13. A PTC resistor according to claim 7, wherein the reactant and reactive resins contain different moieties selected from the group consisting of carboxyl groups, carbonyl groups, hydroxyl groups, ester groups, vinyl groups, amino groups, epoxy groups, oxazoline groups, and maleic anhydride groups.

14. A PTC resistor according to claim 7, wherein the first and second resins have an affinity to each other.

15. A PTC resistor according to claim 7, wherein the other of the first resin and the second resin comprises a moiety selected from the group consisting of carboxyl groups, carbonyl groups, hydroxyl groups, ester groups, vinyl groups, amino groups, epoxy groups, oxazoline groups and maleic anhydride groups.

16. A PTC resistor according to claim 2, wherein at least one of the first and second resins comprises a thermoplastic elastomer.

17. A PTC resistor according to claim 16, wherein the thermoplastic elastomer comprise at least one of an olefin-based thermoplastic elastomer, a styrene-based thermoplastic elastomer, a urethane-based thermoplastic elastomer, and a polyester-based thermoplastic elastomer.

18. A PTC resistor according to claim 16, wherein the thermoplastic elastomer is contained at a content of 5-20 wt. % in the at least one of the first and second resins.

19. A PTC resistor according to claim 2, wherein the at least one first conductive material contains at least one kind of conductive material which is not contained in the at least one second conductive material.

20. A PTC resistor according to claim 2, wherein the at least one first conductive material comprises carbon black, and the at least one second conductive material comprises graphite.

21. A PTC resistor according to claim 2, wherein the at least one first conductive material and the at least one second conductive material each comprise at least one of carbon black, graphite, carbon nanotubes, carbon fibers, conductive ceramic fibers, conductive whiskers, metal fibers, conductive inorganic oxides, and conductive polymer fibers.

22. A PTC resistor according to claim 2, wherein at least one of the at least one first conductive material and the at least one second conductive material is made in the form of flakes.

23. A PTC resistor according to claim 2, wherein at least one of the first and second resins comprise at least one of metal powder and conductive non-metallic powder.

24. A PTC resistor according to claim 2, wherein one of the at least one first conductive material and the at least one second conductive material is contained at a content of 30-90 wt. % in the first or second PTC composition which contains the at least one conductive material.

25. A PTC resistor according to claim 2, wherein one of the at least one first conductive material and the at least one second conductive material is contained at a content of 40-80 wt. % in the first or second PTC composition which contains the at least one conductive material.

26. A PTC resistor according to claim 2, wherein one of the at least one first conductive material and the at least one second conductive material is contained at a content of 60-70 wt. % in the first or second PTC composition which contains the at least one conductive material.

27. A PTC resistor according to claim 2, wherein the other one of the at least one first conductive material and the at least one second conductive material is contained at a content of 20-80 wt. % in the first or second PTC composition which contains the at least one conductive material.

28. A PTC resistor according to claim 2, wherein the other one of the at least one first conductive material and the at least one second conductive material is contained at a content of 30-70 wt. % in the first or second PTC composition which contains the at least one conductive material.

29. A PTC resistor according to claim 2 wherein the other one of the at least one first conductive material and the at least one second conductive material is contained at a content of 30-60 wt. % in the first or second PTC composition which contains the at least one conductive material.

30. A PTC resistor according to claim 2, wherein the PTC resistor has an electric resistivity ranging between 0.0007 Ω

·

m and 0.016 Ω

·

m.

31. A PTC resistor according to claim 2, wherein the PTC resistor has an electric resistivity ranging between 0.0011 Ω

·

m and 0.0078 Ω

·

m

32. A PTC resistor according to claim 2, wherein the PTC resistor exhibits an electric resistivity at 50°

C. which is at least twice as high as the electric resistivity thereof measured at 20°

C.

33. A PTC resistor according to claim 2, wherein at a temperature lower than 50°

C., the PTC resistor exhibits an electric resistivity lower than an electric resistivity of either the first or second PTC composition, while at a temperature above 50°

C., exhibiting an electric resistivity higher than those of the first and second PTC composition.

34. A PTC resistor according to claim 2, wherein the PTC resistor extends by more than 5% with a load of less than 7 kgf.

35. A PTC resistor according to claim 2, wherein the PTC resistor has a thermal expansion coefficient of between 20×

10<sup>−

5</sup>/K and 40×

10<sup>−

5</sup>/K.

36. A PTC resistor according to claim 2, wherein at least one of the first and second PTC compositions comprises a flame retardant agent.

37. A PTC resistor according to claim 36, wherein the flame retardant agent comprises at least one of a phosphorus-based flame retardant, a nitrogen-based flame retardant, a silicone-based flame retardant, an inorganic flame retardant and a halogen-based flame retardant.

38. A PTC resistor according to claim 36, wherein the PTC resistor satisfies at least one of the following conditions:

(a) When an end of the PTC resistor is burned with a gas flame, and the gas flame is extinguished after 60 seconds, the PTC resistor does not burn, even if the PTC resistor is charred;

(b) When an end of the PTC resistor is burned with a gas flame, the PTC resistor catches fire for no more than 60 seconds, but the flame extinguishes within 2 inches;

or

(c) When an end of the PTC resistor is burned with a gas flame, even if the PTC resistor catches fire, the flame does not advance at a rate of 4 inches/minute or more in an area ½

inch thick from the surface.

39. A PTC resistor according to claim 36, wherein the flame retardant agent is contained in the PTC resistor at a content of 5 wt. % or more.

40. A PTC resistor according to claim 36, wherein the flame retardant agent is contained in the PTC resistor at a content of 10-30 wt. %.

41. A PTC resistor according to claim 36, wherein the flame retardant agent is contained in the PTC resistor at a content of 15-25 wt. %.

42. A PTC resistor according to claim 2, wherein the PTC resistor comprises a liquid-resistant resin.

43. A PTC resistor according to claim 42, wherein the liquid-resistant resin is contained at a content of 10 wt. % or more with respect to the first and second PTC compositions.

44. A PTC resistor according to claim 42, wherein the liquid-resistant resin is contained at a content of 10-70 wt. % with respect to the first and second PTC compositions.

45. A PTC resistor according to claim 42, wherein the liquid-resistant resin is contained at a content of 30-50 wt. % with respect to the first and second PTC compositions.

46. A PTC resistor according to claim 42, wherein the liquid-resistant resin comprises at least one of an ethylene/vinyl alcohol copolymer, a thermoplastic polyester resin, a polyamide resin, a polypropylene resin and an ionomer.

47. A PTC resistor according to claim 7, wherein the reactive resin comprises a liquid-resistant resin.