Wet-use plane heater using PTC constant heater-ink polymer

• US 9,668,301 B2
• Filed: 06/01/2016
• Issued: 05/30/2017
• Est. Priority Date: 07/03/2015
• Status: Active Grant

• Current Assignee: NDT Engineering & Aerospace Co., Ltd.
• Original Assignee: NDT Engineering & Aerospace Co., Ltd.
• Inventors: Lim, Ki Hyun, Noh, Chi Woo
• Primary Examiner(s): STAPLETON, ERIC S
• Application Number:
  US15/170,006
• Publication Number:
  US 20170006664A1
• Time in Patent Office: 363 Days
• Field of Search: 219219, 219522, 219528, 2194511, 219541, 219542-544, 219548, 219549, 2194681, 428156, 428202, 428 401, 428 418, 428 421
• CPC Class Codes: H05B 2203/01 Heaters comprising a particular structure with multiple layers
• 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 2203/026 Heaters specially adapted for floor heating
• CPC Class Codes: H05B 2214/04 Heating means manufactured by using nanotechnology
• CPC Class Codes: H05B 3/03 Electrodes
• CPC Class Codes: H05B 3/04 Waterproof or air-tight seals for heaters
• CPC Class Codes: H05B 3/14 the material being non-metallic
• 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 3/286 the insulating material being an organic material, e.g. plastic

Abstract

Provided is a wet-use plane heater using a positive temperature coefficient (PTC) constant heater-ink polymer, wherein the wet-use plane heater has unique characteristics in that it may not only be safe from the damage to the heater and the risk of fire due to self-temperature control characteristics, but a plane heater, which has been mainly installed in dry-use applications due to limitations of leakage current and induced current caused by an increase in contact area with an installation floor, may also be used for wet installation which uses a mortar.

Claims

1. A wet-use plane constant heater using a positive temperature coefficient (PTC) constant heater-ink polymer with self-temperature control characteristics in which a PTC element and multi-walled carbon nanotubes (MWNT), as conductive fine particles, are combined, the wet-use plane heater comprising:

a lower laminated portion (A) which includes first and second adhesives for laminating a pair of polypropylene (PP) films with a polyethylene terephthalate (PET) film to minimize a leakage current generated due to moisture permeability and waterproofing properties in the PET film having a thin planar shape, heat resistance and insulating properties on which metal electrodes are mounted, a third adhesive for lamination of an ester-based nonwoven fabric to bond the PP film, prevent movement of the metal electrodes, and minimize the leakage current, and a double-sided adhesive tape to which a release paper for attaching the nonwoven fabric to an installation floor surface is attached; and

an upper laminated portion (B) which includes first and second adhesives for laminating a pair of polypropylene (PP) films with a polyethylene terephthalate (PET) film to minimize a leakage current generated due to moisture permeability and waterproofing properties in the PET film having a thin planar shape, heat resistance and insulating properties on which metal electrodes are mounted, and a third adhesive for laminating the PP film with an ester-based nonwoven fabric configured to improve adhesion with a mortar disposed on a top thereof,

wherein the PET film and the PP films, as insulating films of the lower laminated portion (A) laminated with the first and second adhesives, the PET film and the PP films, as insulating films of the upper laminated portion (B) laminated with the first and second adhesives, and the ester-based nonwoven fabrics laminated with the third adhesives are partially laminated by a dry lamination method using a gravure copper plate and polyurethane including a hardener and heat-treated to minimize an induced current which is generated from the plane heater due to an increase in contact area with an installation floor when a voltage is applied to the metal electrodes of the constant heater.

2. The wet-use plane heater using a PTC constant heater-ink polymer of claim 1, wherein the metal electrodes are copper (Cu) having excellent thermal conductivity and electrical conductivity.

3. The wet-use plane heater using a PTC constant heater-ink polymer of claim 1, wherein the PET film and the PP films, as insulating films of the lower laminated portion (A) laminated with the first and second adhesives, the PET film and the PP films, as fabric films of the upper laminated portion (B) laminated with the first and second adhesives, and the ester-based nonwoven fabrics laminated with the third adhesives are overall laminated by a dry lamination method using the gravure copper plate and polyurethane including a hardener and heat-treated.

4. The wet-use plane heater using a PTC constant heater-ink polymer of claim 1, wherein the metal electrodes disposed between the PET film and the PET film are mounted in 4 lines when the wet-use plane heater is for AC 200V to 250 V.

5. The wet-use plane heater using a PTC constant heater-ink polymer of claim 1, wherein the metal electrodes disposed between the PET film and the PET film are mounted in 6 lines when the wet-use plane heater is for AC 100V to 150 V.

6. The wet-use plane heater using a PTC constant heater-ink polymer of claim 1, wherein an adhesive is coated in a rhombus cell pattern having a predetermined interval to form an air layer for the minimization of the leakage current when using the partial lamination.

7. The wet-use plane heater using a PTC constant heater-ink polymer of claim 1, wherein an adhesive is coated in a longitudinal cell pattern having a predetermined interval to improve deformation of an air layer formed for the minimization of the leakage current, ripples of the metal electrodes, and wrinkles and waves on the constant heater when using the partial lamination.