Activated carbon fiber soft electric heating product and manufacturing method thereof

• US 20100062667A1
• Filed: 09/11/2008
• Published: 03/11/2010
• Est. Priority Date: 09/11/2008
• Status: Active Grant

• Current Assignee: Ching-Ling Pan
• Original Assignee: Ching-Ling Pan, Yung-Shun Wu
• Inventors: Pan, Ching-Ling, Wu, Yung-Shun
• Granted Patent: US 7,827,675 B2
• Time in Patent Office: Days
• US Class Current: 442/102
• CPC Class Codes: B32B 2250/20 All layers being fibrous or filamentary
• CPC Class Codes: B32B 2255/02 on fibrous or filamentary layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2262/062 Cellulose fibres, e.g. cotton
• CPC Class Codes: B32B 2262/103 Metal fibres
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2307/202 Conductive
• CPC Class Codes: B32B 2307/30 having particular thermal properties
• CPC Class Codes: B32B 2307/302 Conductive
• CPC Class Codes: B32B 2307/546 Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2309/02 Temperature
• CPC Class Codes: B32B 2309/04 Time
• CPC Class Codes: B32B 2309/12 Pressure
• CPC Class Codes: B32B 2313/04 Carbon
• CPC Class Codes: B32B 2363/00 Epoxy resins
• CPC Class Codes: B32B 2437/00 Clothing
• CPC Class Codes: B32B 2479/00 Furniture
• CPC Class Codes: B32B 2509/00 : Household appliances
• CPC Class Codes: B32B 2535/00 : Medical equipment, e.g. bandage, prostheses or catheter
• CPC Class Codes: B32B 2605/003 : Interior finishings
• CPC Class Codes: B32B 3/08 : characterised by added members at particular parts layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/028 : Net structure, e.g. spaced apart filaments bonded at the crossing points
• CPC Class Codes: B32B 5/06 : characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: H05B 2203/011 : Heaters using laterally extending conductive material as connecting means
• CPC Class Codes: H05B 2203/017 : Manufacturing methods or apparatus for heaters
• CPC Class Codes: H05B 2203/032 : Heaters specially adapted for heating by radiation heating
• CPC Class Codes: H05B 2203/036 : Heaters specially adapted for garment heating
• CPC Class Codes: H05B 3/342 : heaters used in textiles
• CPC Class Codes: Y10T 29/49083 : Heater type
• CPC Class Codes: Y10T 29/49087 : with envelope or housing
• CPC Class Codes: Y10T 29/49098 : Applying terminal
• CPC Class Codes: Y10T 29/49099 : Coating resistive material on a base
• CPC Class Codes: Y10T 29/49124 : On flat or curved insulated base, e.g., printed circuit, etc.
• CPC Class Codes: Y10T 442/2352 : Coating or impregnation functions to soften the feel of or improve the "hand" of the fabric

Abstract

An activated carbon fiber soft electric heating product and its manufacturing method for overcoming existing problems including uneven temperature rise and heat dissipation at surfaces of the product, unbendable feature, short life and poor safety. An activated carbon fiber cloth and a woven fiber cloth of the activated carbon fiber soft electric heating product are fixed by an epoxy resin layer, and a conducting copper net is disposed between the activated carbon fiber cloth and the epoxy resin layer and coupled to a power input wire. The manufacturing method includes the steps of: (1) spraying an epoxy resin on a surface of the woven fiber cloth, and bake-drying and hot pressing the woven fiber cloth; and (2) connecting the conducting copper net and the power input wire, laying the activated carbon fiber cloth, and performing a second-time hot pressing. Meanwhile, carbon fiber constitutes a heat generating surface with the advantages of a light weight, a soft texture, a bendable feature, a uniform electric heating performance, a fast temperature rise, a highly safe, reliable and long life feature. In addition, the method of the invention involves a simple technical skill and an easy operation.

Claims

1. An activated carbon fiber soft electric heating product, comprising a woven fiber cloth, an epoxy resin layer, a conducting copper net, an activated carbon fiber cloth and a power input wire, and an epoxy resin layer being disposed between the woven fiber cloth and the activated carbon fiber cloth, and a conducting copper net being disposed between the activated carbon fiber cloth and the epoxy resin layer, and the conducting copper net being coupled to the power input wire.

2. The activated carbon fiber soft electric heating product of claim 1, wherein the activated carbon fiber cloth is made by weaving an inorganic fiber into an inorganic fiber cloth, and going though a soaking process, a bake-drying process, two times of carbonization, two times of activation, and the ash content of the activated carbon fiber cloth is 0.5˜

1.5% (by weight), and the carbon content of the activated carbon fiber cloth is 95˜

98% (by weight).

3. A method of manufacturing an activated carbon fiber soft electric heating product as recited in claim 1, comprising the steps of:

(1) spraying epoxy resin on a side of a surface of the woven fiber cloth, drying the woven fiber cloth at a temperature of 80˜

100°

C. for 5˜

10 min, and hot pressing the woven fiber cloth at a temperature of 120˜

140°

C. and a pressure of 200˜

250 kg/cm² for 3˜

5 min, and the hot pressing temperature remaining constant during the hot pressing process, so as to obtain an epoxy resin layer on a side of the surface of the woven fiber cloth; and

(2) sewing a conducting copper net on both ends of a surface of the epoxy resin layer of the woven fiber cloth, and coupling the conducting copper net with a power input wire, and laying the epoxy resin layer flatly on the activated carbon fiber cloth, and performing a second-time hot pressing the woven fiber cloth at a temperature of 160˜

180°

C., and a pressure of 250˜

400 kg/cm² for 6˜

8 min, and the hot pressing temperature remaining constant during the second-time hot pressing process, so as to obtain the activated carbon fiber soft electric heating product.

4. The method of manufacturing an activated carbon fiber soft electric heating product as recited in claim 3, wherein the step (1) has a hot pressing temperature of 125°

C.˜

135°

C. and a hot pressing pressure of 220 kg/cm²˜

240 kg/cm².

5. The method of manufacturing an activated carbon fiber soft electric heating product as recited in claim 3, wherein the step (2) has a second-time hot pressing temperature of 165°

C.˜

175°

C. and a second-time hot pressing pressure is 300 kg/cm²˜

350 kg/cm².

6. The method of manufacturing an activated carbon fiber soft electric heating product as recited in claim 3, wherein the Step (2) of manufacturing the activated carbon fiber cloth comprises the steps of weaving an inorganic fiber into an inorganic fiber cloth and going through a soaking process, a bake-drying process, two times of carbonization, two times of activation, and an ash content of the activated carbon fiber cloth is 0.5˜

1.5% (by weight), and a carbon content of the activated carbon fiber cloth is 95˜

98% (by weight).

7. The method of manufacturing an activated carbon fiber soft electric heating product as recited in claim 6, wherein the method of manufacturing the activated carbon fiber cloth comprises the steps of:

(a) weaving an inorganic fiber into an inorganic fiber cloth, and soaking the inorganic cloth for 0.5˜

1 hour, and bake-drying the inorganic cloth at 80˜

100°

C. until the water content percentage is 1˜

10%;

(b) performing two times of carbonization to the inorganic fiber cloth of Step (a) in a carbonization furnace, and the first-time carbonization takes place at a temperature of 200˜

350°

C., and a speed of 20˜

40 m/h, and the second-time carbonization takes place at a temperature of 300˜

480°

C. and a speed of 40˜

60 m/h;

(c) performing two times of activation to the inorganic fiber cloth obtained from the Step (b) in an activation furnace, and the first-time activation takes place at a temperature of 500˜

1200°

C., and the second-time activation takes place at a temperature of 600˜

950°

C., and the activation speeds for both times are 50˜

60 m/h; and

(d) removing any attached matter on the surface of the inorganic fiber cloth by a vacuum cleaner after the activation to obtain the activated carbon fiber cloth.

8. The method of manufacturing an activated carbon fiber soft electric heating product as recited in claim 7, wherein the soaking solution for Step (a) is ammonium bromide solution with a concentration of 5˜

10% (by weight).

9. The method of manufacturing an activated carbon fiber soft electric heating product as recited in claim 7, wherein the first-time carbonization in Step (b) takes place at a temperature of 240°

C.˜

300°

C. while the second-time carbonization is done at a temperature of 350°

C.˜

450°

C.

10. The method of manufacturing an activated carbon fiber soft electric heating product as recited in claim 7, wherein the first-time activation in Step (c) takes place at a temperature of 600°

C.˜

1000°

C. while the second-time activation is done at a temperature of 700°

C.˜

900°

C.