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 9,955,531 B2
• Filed: 01/23/2015
• Issued: 04/24/2018
• Est. Priority Date: 06/18/2014
• Status: Active Grant

• Current Assignee: Suk Hwan Kang
• Original Assignee: Suk Hwan Kang
• Inventors: Kang, Suk Hwan, Nah, Jong Bok, Won, Jeong Ha
• Primary Examiner(s): Angwin, David
• Assistant Examiner(s): Bae, Gyounghyun
• Application Number:
  US14/603,649
• Publication Number:
  US 20150373782A1
• Time in Patent Office: 1,187 Days
• Field of Search: None
• 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

A manufacturing method of a PTC (Positive Temperature Coefficient) element includes: producing a polymer aqueous emulsion solution; producing a polymer aqueous emulsion conductive composite by mixing the polymer aqueous emulsion solution with a conductive agent; and producing the PTC element by coating a substrate with the polymer aqueous emulsion conductive composite, or print the polymer aqueous emulsion conductive composite on the substrate, or dipping the substrate in the polymer aqueous emulsion conductive composite and drying the substrate. Here, 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.

Claims

1. A manufacturing method of a positive temperature coefficient (PTC) planar heating 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 planar heating element by coating a substrate with the polymer aqueous emulsion conductive composite, printing a pattern on the substrate with the polymer aqueous emulsion conductive composites, or dipping the substrate in the polymer aqueous emulsion conductive composite and drying the substrate coated with the polymer aqueous emulsion conductive composite,

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

an adhesive polymer of 30 to 70 weight %;

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

an initiator of 0.5 to 1 weight %; and

the remaining water, and

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

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

a conductive agent of 30 to 70 weight %.

2. The manufacturing method 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.

3. The manufacturing method 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.

4. The manufacturing method 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.

5. The manufacturing method 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.

6. The manufacturing method 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.

7. A manufacturing method of a positive temperature coefficient (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 the conductive yarn or the non-conductive yarn in the polymer aqueous emulsion conductive composite and drying the conductive yarn or the non-conductive yarn coated with 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 %;

an adhesive polymer of 30 to 70 weight %;

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

an initiator of 0.5 to 1 weight %; and

the remaining water, and

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

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

a conductive agent of 30 to 70 weight %.

8. The manufacturing method as claimed in claim 7, 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.

9. The manufacturing method as claimed in claim 7, wherein the cross-linking agent is one or more selected from divinyl benzene, diene monomer, trimethylolpropane trivinyl ether monomer, and vinyl trimethoxysilane monomer.

10. The manufacturing method as claimed in claim 7, wherein the initiator is one or more selected from dicumyl peroxide, acetyl benzoyl peroxide, tert-butyl hydroperoxide, and diacetyl peroxide.

11. The manufacturing method as claimed in claim 7, 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 as claimed in claim 7, 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.