MANUFACTURING METHOD OF PTC ELEMENT USING POLYMER AQUEOUS EMULSION CONDUCTIVE COMPOSITE, PTC ELEMENT MANUFACTURED BY MANUFACTURING METHOD, AND PLANAR HEATING ELEMENT INCLUDING PTC ELEMENT

• US 20150373782A1
• Filed: 01/23/2015
• Published: 12/24/2015
• Est. Priority Date: 06/18/2014
• Status: Active Grant

• Current Assignee: Suk Hwan Kang
• Original Assignee: Uniplatek Co., Ltd.
• Inventors: KANG, Suk Hwan, NAH, Jong Bok, WON, Jeong Ha
• Granted Patent: US 9,955,531 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: D06M 11/74 with carbon or graphite; with carbides; with graphitic acids or their salts
• CPC Class Codes: D06M 15/00 Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment D06M10/00, D06M14/00 take precedence; treatment with inorganic polyphosphates D06M11/72
• CPC Class Codes: D06M 2101/40 Fibres of carbon
• CPC Class Codes: D06N 3/0063 Inorganic compounding ingredients, e.g. metals, carbon fibres, Na2CO3, metal layers; Post-treatment with inorganic compounds
• 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 2203/02 Heaters using heating elements having a positive temperature coefficient
• CPC Class Codes: H05B 3/146 Conductive polymers, e.g. polyethylene, thermoplastics
• CPC Class Codes: H05B 3/34 flexible, e.g. heating nets or webs

Abstract

The present invention relates to a PTC (Positive Temperature Coefficient) element manufactured using a polymer aqueous emulsion conductive composite, and a planar heating element using the same. By controlling electric connection of the heating element using the PTC element, it is possible to control a heating temperature of the heating element to be in a desired range and to improve stability of the heating element. It is easy to manufacture the PTC manufactured using the polymer aqueous emulsion conductive composite, and PTC characteristics thereof can be satisfactorily kept even in use for a long period. Since the planar heating element manufactured using the PTC element has a self temperature control function, a separate temperature control device is unnecessary, which is economical.

A manufacturing method of a PTC element includes: (1) producing a polymer aqueous emulsion solution; (2) producing a polymer aqueous emulsion conductive composite by mixing the polymer aqueous emulsion solution with a conductive agent; and (3) producing a PTC element by coating or dipping and drying a substrate with the polymer aqueous emulsion conductive composite. The polymer aqueous emulsion solution includes an adhesive polymer, a cross-linking agent, an initiator, and water. The substrate is film, non-woven, textile, inflexible plate, and the like, which are formed of polymer resin. A planar heating element is manufactured by attaching electrodes to the PTC element, and laminating an insulating coating material on upper and lower faces of the PTC element.

Claims

1. A manufacturing method of a PTC element using a polymer aqueous emulsion conductive composite comprising:

(1) producing a polymer aqueous emulsion solution;

(2) producing a polymer aqueous emulsion conductive composite by mixing the polymer aqueous emulsion solution with a conductive agent; and

(3) producing a PTC element by coating a substrate with the polymer aqueous emulsion conductive composite, printing a pattern on the substrate with the polymer aqueous emulsion conductive composite, or dipping and drying the substrate in the polymer aqueous emulsion conductive composite,

wherein the polymer aqueous emulsion solution includes, based on total 100 weight %;

(1) an adhesive polymer of 30 to 70 weight %;

(2) a cross-linking agent of 10 to 40 weight %;

(3) an initiator of 0.5 to 1 weight %; and

(4) the remaining water, and

wherein the polymer aqueous emulsion conductive composite includes, based on total 100 weight %;

(1) the polymer aqueous emulsion solution of 30 to 70 weight %; and

(2) a conductive agent of 30 to 70 weight %.

3. The manufacturing method of a PTC element using a polymer aqueous emulsion conductive composite as claimed in claim 1, wherein the adhesive polymer is one or more selected from ethylene butyl acrylate copolymer, ethylene vinyl acetate copolymer, polyethylene oxide, polyethylene, polypropylene, polyacrylonitrile, polyamide, polyester, syndiotactic polystyrene, polyketone, and cellulose.

5. The manufacturing method of a PTC element using a polymer aqueous emulsion conductive composite as claimed in claim 1, wherein the cross-linking agent is one or more selected from divinyl benzene, diene monomer, trimethylolpropane trivinyl ether monomer, and vinyl trimethoxysilane monomer.

7. The manufacturing method of a PTC element using a polymer aqueous emulsion conductive composite as claimed in claim 1, wherein the initiator is one or more selected from dicumyl peroxide, acetyl benzoyl peroxide, tert-butyl hydroperoxide, and diacetyl peroxide.

9. The manufacturing method of a PTC element using a polymer aqueous emulsion conductive composite as claimed in claim 1, wherein the conductive agent is one or more selected from carbon powder (carbon black), graphite powder, carbon fiber, and carbon nanotube.

11. The manufacturing method of a PTC element using a polymer aqueous emulsion conductive composite as claimed in claim 1, wherein the substrate includes one or more selected from a polymer resin film that is one or more selected from polyethylene terephthalate (PET) film, polyimide film, polyamide film, polyester film, polypropylene film, polyethylene film, polyvinyl chloride film, polyvinylidene chloride film, polycarbonate film, acetate cellulose film, acetate film, polyvinyl alcohol film, polystyrene film, polymer resin, and fluorine resin film, non-woven, textile, paper, slate, mud plate, woodblock, plate glass, plastic plate, cardboard, conductive polymer resin film, conductive non-woven, conductive textile, conductive paper, conductive slate, conductive mud plate, conductive woodblock, conductive plate glass, conductive plastic plate, and conductive cardboard.

13. A PTC element using a polymer aqueous emulsion conductive composite, manufactured by the manufacturing method according to claim 1.

15. A planar heating element using a polymer aqueous emulsion conductive composite, configured by attaching a pair of electrodes to both ends of the PTC element according to claim 13 in parallel or attaching two or more pairs of electrodes to both ends and between both ends at a regular interval and laminating at least one insulating coating material on upper and lower faces of the PTC element.

17. The planar heating element using a polymer aqueous emulsion conductive composite as claimed in claim 15,

wherein in the electrode,

the non-conductive yarn formed of one or more fiber selected from the group consisting of polyester, acrylic (acrylonitrile that is a main component is equal to or more than 50%), acrylic (acrylonitrile that is a main component is 40 to 50%), nylon, vinylon, PVA, polypropylene, polyethylene, vinylidene, polyvinyl chloride, polyvinylidene chloride, aramid, polystyrene, polychlal, benzoid, rayon, polynosic, cupra, acetate, triacetate, promix, polyfluoroethylene, cotton, flax, and ramie is formed of a core fiber, and

2 to 5 plaited lines formed by plaiting 2 to 10 electric wires formed by winding one or more metal thin film line selected from a copper thin film and an aluminum thin film on the core fiber are plaited with one or more metal yarn selected from stainless yarn, nickel yarn, copper yarn, and steel yarn.

2. A manufacturing method of a PTC element using a polymer aqueous emulsion conductive composite comprising:

(1) producing a polymer aqueous emulsion solution;

(2) producing a polymer aqueous emulsion conductive composite by mixing the polymer aqueous emulsion solution with a conductive agent;

(3) producing a fabric coated with the conductive composite by coating conductive yarn or non-conductive yarn with the polymer aqueous emulsion conductive composite, or dipping and drying the conductive yarn or the non-conductive yarn in the polymer aqueous emulsion conductive composite; and

(4) producing a non-woven or textile PTC element using the fabric coated with the conductive composite,

wherein the polymer aqueous emulsion solution includes, based on total 100 weight %;

(1) an adhesive polymer of 30 to 70 weight %;

(2) a cross-linking agent of 10 to 40 weight %;

(3) an initiator of 0.5 to 1 weight %; and

(4) the remaining water, and

wherein the polymer aqueous emulsion conductive composite includes, based on total 100 weight %;

(1) the polymer aqueous emulsion solution of 30 to 70 weight %; and

(2) a conductive agent of 30 to 70 weight %.

4. The manufacturing method of a PTC element using a polymer aqueous emulsion conductive composite as claimed in claim 2, wherein the adhesive polymer is one or more selected from ethylene butyl acrylate copolymer, ethylene vinyl acetate copolymer, polyethylene oxide, polyethylene, polypropylene, polyacrylonitrile, polyamide, polyester, syndiotactic polystyrene, polyketone, and cellulose.

6. The manufacturing method of a PTC element using a polymer aqueous emulsion conductive composite as claimed in claim 2, wherein the cross-linking agent is one or more selected from divinyl benzene, diene monomer, trimethylolpropane trivinyl ether monomer, and vinyl trimethoxysilane monomer.

8. The manufacturing method of a PTC element using a polymer aqueous emulsion conductive composite as claimed in claim 2, wherein the initiator is one or more selected from dicumyl peroxide, acetyl benzoyl peroxide, tert-butyl hydroperoxide, and diacetyl peroxide.

10. The manufacturing method of a PTC element using a polymer aqueous emulsion conductive composite as claimed in claim 2, wherein the conductive agent is one or more selected from carbon powder (carbon black), graphite powder, carbon fiber, and carbon nanotube.

12. The manufacturing method of a PTC element using a polymer aqueous emulsion conductive composite as claimed in claim 2, wherein the non-conductive yarn is one or more fiber selected from polyester, acrylic of acrylonitrile of 50 to 100 weight %, acrylic including acrylonitrile 40 to 50 weight %, nylon, vinylon, PVA, polypropylene, polyethylene, vinylidene, polyvinyl chloride, polyvinylidene chloride, aramid, polystyrene, polychlal, benzoid, rayon, polynosic, cupra, acetate, triacetate, promix, polyfluoroethylene, cotton, flax, and ramie, and

wherein the conductive yarn is one or more fiber selected from:

a thing produced by mixing a fiber conductive material and non-conductive yarn;

a thing produced by melting, mixing, and weaving conductive powder and polymer resin;

metal yarn;

a partially carbonized carbon fiber acquired at a yield of 25 to 70 weight % to the initial weight by carbonizing PAN-based carbon fiber or pitch-based carbon fiber in an inert atmosphere at a medium temperature of 600 to 1500°

C.;

a cotton yarn made by spinning the conductive yarn and the non-conductive yarn together;

conductive yarn coated with a conductive material; and

conductive yarn in which non-conductive yarn is a core material, an outside thereof is covered with a metal yarn to broaden a sectional area of current flow.

14. A PTC element using a polymer aqueous emulsion conductive composite, manufactured by the manufacturing method according to claim 2.

16. A planar heating element using a polymer aqueous emulsion conductive composite, configured by attaching a pair of electrodes to both ends of the PTC element according to claim 14 in parallel or attaching two or more pairs of electrodes to both ends and between both ends at a regular interval and laminating at least one insulating coating material on upper and lower faces of the PTC element.

18. The planar heating element using a polymer aqueous emulsion conductive composite as claimed in claim 16,

wherein in the electrode,

the non-conductive yarn formed of one or more fiber selected from the group consisting of polyester, acrylic (acrylonitrile that is a main component is equal to or more than 50%), acrylic (acrylonitrile that is a main component is 40 to 50%), nylon, vinylon, PVA, polypropylene, polyethylene, vinylidene, polyvinyl chloride, polyvinylidene chloride, aramid, polystyrene, polychlal, benzoid, rayon, polynosic, cupra, acetate, triacetate, promix, polyfluoroethylene, cotton, flax, and ramie is formed of a core fiber, and

2 to 5 plaited lines formed by plaiting 2 to 10 electric wires formed by winding one or more metal thin film line selected from a copper thin film and an aluminum thin film on the core fiber are plaited with one or more metal yarn selected from stainless yarn, nickel yarn, copper yarn, and steel yarn.