EP0824847A1 - Heating element, fabrication process and application - Google Patents

Heating element, fabrication process and application

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Publication number
EP0824847A1
EP0824847A1 EP96910147A EP96910147A EP0824847A1 EP 0824847 A1 EP0824847 A1 EP 0824847A1 EP 96910147 A EP96910147 A EP 96910147A EP 96910147 A EP96910147 A EP 96910147A EP 0824847 A1 EP0824847 A1 EP 0824847A1
Authority
EP
European Patent Office
Prior art keywords
heating element
substrate
element according
layer
binder
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP96910147A
Other languages
German (de)
French (fr)
Other versions
EP0824847B1 (en
Inventor
Dominique Petit
Peter Wolki
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Saint Gobain Performance Plastics Corp
Original Assignee
Norton Pampus GmbH
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Filing date
Publication date
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Application filed by Norton Pampus GmbH filed Critical Norton Pampus GmbH
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Application granted granted Critical
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Classifications

    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
    • H05B3/22—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible
    • H05B3/28—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor embedded in insulating material
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
    • D06F75/00—Hand irons
    • D06F75/08—Hand irons internally heated by electricity
    • D06F75/24—Arrangements of the heating means within the iron; Arrangements for distributing, conducting or storing the heat
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
    • D06F75/00—Hand irons
    • D06F75/08—Hand irons internally heated by electricity
    • D06F75/26—Temperature control or indicating arrangements
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
    • H05B3/22—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible
    • H05B3/28—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor embedded in insulating material
    • H05B3/283—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor embedded in insulating material the insulating material being an inorganic material, e.g. ceramic
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
    • H05B3/22—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible
    • H05B3/28—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor embedded in insulating material
    • H05B3/286—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor embedded in insulating material the insulating material being an organic material, e.g. plastic
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/002—Heaters using a particular layout for the resistive material or resistive elements
    • H05B2203/003—Heaters using a particular layout for the resistive material or resistive elements using serpentine layout

Definitions

  • the present invention relates to a new electric heating element in the form of a film or thin sheet with a laminated structure comprising at least one electrically conductive layer and at least one substrate.
  • Electric heating elements used in household applications such as irons, grills, etc. are formed of resistance wires embedded in an insulating ceramic material, itself placed in a metallic envelope.
  • One drawback of this type of electric heating element is its thermal inertia.
  • Another disadvantage is that it does not lend itself to complex contours.
  • Electric heating elements in the form of sheets with several layers are also known: an electrically conductive layer formed of a thin metallic film, bonded to a substrate by means of a hot-melt adhesive layer which must resist the heat.
  • Suitable hot-melt layers are extruded films with a thickness generally greater than 20 ⁇ m.
  • This heating element is the low conductivity of the hot-melt film. This low conductivity can also not be improved appreciably by the incorporation of heat conducting charges in the extruded layer.
  • the invention overcomes the disadvantages mentioned. It offers a heating element in the form of a thin film, with low thermal inertia and the manufacture of which is simplified.
  • the heating element according to the invention comprises at least one substrate and at least one layer of electrical resistance adhering to the substrate by a binder formed from a dispersion or solution or powder deposited directly on the substrate.
  • the binder according to the invention can be chosen from dispersions or solutions or powders of at least one polymer (or copolymer), the melting point of which is higher than the operating temperature of the heating element and which can be deposited on a substrate, if necessary under a thin thickness.
  • the polymer is chosen from perfluorinated polymers, in particular perfluoro-alkoxy-alkane (PFA), MFA, polytetrafluoroethylene (PTFE).
  • a dispersion or solution is chosen of at least one of the polymers mentioned above and which can be heavily charged if necessary by heat conducting charges and electrically insulating, for example oxide aluminum AI 2 O 3 , silicon carbide SiC, mica, glass powder.
  • the substrate according to the invention which has in particular a mechanical support function for the heating element, as well as an electric insulator function, can be any sheet selected according to the application envisaged for the heating element.
  • This sheet may be based on a thermoplastic or thermosetting material or on a cellulosic material, or a fabric or veil of glass impregnated or not, based on ceramic fibers, or an extruded or unwound sheet.
  • thermoplastic or thermosetting material is chosen in particular from polytetrafluoroethylene (PTFE), perfluoro-alkoxy-alkane (PFA), MFA, perfluoro (ethylene-propylene) (FEP), ethylene-tetrafluoroethylene (ETFE), fluoride poly (vinylidene) (PVDF), polyethylene terephthalate (PET), polyimide (KAPTON).
  • PTFE polytetrafluoroethylene
  • PFA perfluoro-alkoxy-alkane
  • MFA perfluoro (ethylene-propylene)
  • FEP ethylene-tetrafluoroethylene
  • ETFE ethylene-tetrafluoroethylene
  • PVDF fluoride poly (vinylidene)
  • PET polyethylene terephthalate
  • KAPTON polyimide
  • the substrate generally has a thickness of between 20 ⁇ m and 500 ⁇ m or more if necessary, depending on the application.
  • the electrical resistance layer is a film or a thin sheet of an electrically conductive material, in particular based on a metal such as copper, nickel, aluminum or an alloy of metals such as bronze, brass, Constantan R.
  • a metal such as copper, nickel, aluminum or an alloy of metals such as bronze, brass, Constantan R.
  • this can have on at least one of its two faces a structured surface obtained for example by rolling in a calendering machine provided with rollers with structured surface or a rough surface obtained for example by sandblasting or abrasive treatment.
  • the conductive metal sheet can alternatively be replaced by an electrically conductive fabric or by a layer formed by a carpet of electrically conductive fibers.
  • the thickness of the conductive thin film can be calculated according to the conductor and the application envisaged for the heating element, that is to say according to the desired electrical power.
  • the conductive film can have the form of a serpentine circuit.
  • a serpentine circuit Such a form is obtained for example from a continuous film which is treated in places by chemical etching, using in particular a mixture of hydrochloric acid and hydrogen peroxide.
  • the electrical resistance is obtained directly with the desired shape by depositing on the substrate an electrically conductive composition, for example by screen printing, by electrostatic spraying with the use of a stencil, etc.
  • the electrical resistance layer merges with the binder layer which for this purpose is heavily loaded with particles in the form of powder or fibers of electrically conductive material, for example metallic particles or coated particles of metal, or even graphite.
  • the heating element according to the invention generally also comprises an electrical insulating coating covering the electrical resistance layer.
  • This coating is for example a second substrate of the type of the first substrate described above, which can adhere to the electrical resistance layer via another adhesive layer.
  • composition of the heating element from thin layers gives it a low thickness, which results in a very reduced thermal inertia.
  • the invention also relates to a method for manufacturing the heating element.
  • the substrate, the binder and the electrically conductive layer used are chosen from the products described above.
  • the method uses the following steps: - the substrate to be used as a support, at least intermediate, is prepared for the production of the heating element,
  • the binder is deposited on the substrate from a dispersion or solution or a powder of this binder
  • the conductive layer which is in particular in the form of a metallic film, is assembled by pressing, for example by pressing between the plates of a press or by calendering between rollers, with the substrate coated with the binder,
  • the conductive layer is chemically treated, in particular by chemical etching, in order to give this layer the desired shape for the electrical resistance,
  • a second substrate coated with a binder layer is assembled by pressing with the prelaminated element by placing the binder layer of the second substrate in contact with the conductive layer, - finally the heating element with a laminated structure, of low thickness and low thermal inertia.
  • binder solution or dispersion makes it possible to obtain thin layers and, nevertheless, very good adhesion between the elements of the laminate, and which is preserved over time and under the most extreme conditions of use.
  • the manufacturing process uses the following operations:
  • the electrically conductive composition is deposited on the prepared substrate using a screen printing screen or a stencil, - the deposited layer is dried,
  • a second substrate coated with a layer of binder is assembled by pressing with the substrate coated with the heating resistor.
  • the electrical resistance is finally embedded in the binder layer of the second substrate.
  • the manufacturing process can then use the following operations:
  • a dispersion of the binder and electrically conductive particles is deposited on the prepared substrate, - after optional drying of the deposited layer, this layer containing the metallic particles is chemically treated so as to give it the desired shape for the electrical resistance ,
  • a second substrate coated with a layer of binder is assembled by pressing with the substrate coated with the electrical resistance previously prepared.
  • FIG. 1 represents the different stages of the manufacture of an example of a heating element according to the invention using a metal film as an electric heating resistance.
  • FIG. 2 represents the various stages of the manufacture of an example of a heating element according to the invention using a layer based on metallic particles as an electric heating resistance.
  • FIG. 3 and 4 show a heating element according to the invention provided with a thermostat.
  • FIG. 5 represents an application for heating elements according to the invention.
  • the substrate 1 serving as a support is a sheet formed from a glass fabric impregnated with PTFE 80 ⁇ m thick.
  • a coating 2 of PFA dispersed in water is deposited by the coating technique using a doctor blade or a pencil. After drying at a temperature of 350 ° C., a layer of
  • a metal sheet 4 50 ⁇ m thick is deposited in Constantan and these elements are assembled by pressing between the plates of a press, under a pressure of 40 bars at 350 ° C. for a few minutes.
  • the assembly After having protected with a varnish deposited by screen printing the parts of the metal sheet intended to form the electrical resistance, the assembly is treated with a mixture of hydrochloric acid and hydrogen peroxide in order to obtain the desired shape for the heating resistance by chemical etching.
  • a prelaminated element 5 is obtained.
  • a thin heating element 8 is finally obtained which can be cut to the desired dimensions and which can be used in various applications.
  • the cutting can be carried out at the level of the prefabricated element, the coating with the second substrate taking place on the precast elements cut out.
  • the substrate 9 serving as a support can be the same as that described in relation to FIG. 1.
  • a dispersion 10 containing PFA and electrically conductive metal particles is deposited on this PTFE-based substrate.
  • the content of metal particles is determined so as to have a continuous electrical contact in the coating layer 11 formed on the substrate after drying. This content depends in particular on the dimensions and the shape of the metallic particles. Then the chemical etching of the conductive coating layer 1 1 is carried out and a prelaminated element 1 2 is obtained.
  • This prelaminated element 1 2 is then assembled with a second substrate 1 3 coated in this example with the layer 14 of binder based on PFA.
  • a thin heating element 15 is obtained which can be cut to the desired dimensions. Alternatively, the cutting takes place at the prefabricated elements (prelaminated).
  • the heating element according to the invention can be used both in household applications and in industrial applications which require the use of heating elements of small thickness and low thermal inertia. Several heating elements can be used in combination.
  • the heating element can also be used with advantage in aggressive environments such as treatment baths.
  • the heating element can be more or less flexible depending on the conductive layers and the applications envisaged.
  • the heating element can be used in a flat or thermoformed form, especially when it comes to stiffening it. It can still be used thanks to its thin thickness in the form of a ribbon wound for example around tubes. It can also optionally be provided with an adhesive layer so as to ensure the connection with the object to be heated.
  • the heating element according to the invention can also be provided with a thermostat in the form of a flat thermocouple placed in an adhesive layer adjacent to a substrate.
  • a thermostat in the form of a flat thermocouple placed in an adhesive layer adjacent to a substrate.
  • An embodiment of such a heating element is shown schematically in Figures 3 and 4.
  • This heating element 1 6 comprises a first substrate 1 7, an adhesive layer 1 8 containing the heating resistor 1 9, a second substrate 20, a second layer adhesive 21 containing a thermocouple 22 and a third substrate 23.
  • the proximity of the thermocouple 22 of the heating resistor allows very rapid temperature regulation.
  • FIG. 5 is shown an application which uses several heating elements according to the invention.
  • three heating elements 24, 25, 26 are arranged in the sole 27 of an iron.
  • These three heating elements can have the same electrical resistivity or, alternatively, different constant or variable resistivities depending on the temperature.
  • Each heating element corresponds to a heating zone which can if necessary be controlled separately by a thermostat or alternatively by the resistive layer itself. This arrangement in combination allows very good control of the temperature of the sole regardless of the ironing method used.

Abstract

PCT No. PCT/IB96/00390 Sec. 371 Date Feb. 19, 1998 Sec. 102(e) Date Feb. 19, 1998 PCT Filed Apr. 30, 1996 PCT Pub. No. WO96/35317 PCT Pub. Date Nov. 7, 1996A heating element includes at least one substrate, at least one electrical resistance layer, and a binder configured to bind the electrical resistance layer to the substrate, wherein the binder has a melting temperature greater than an operating temperature of the heating element and includes a perfluorinated polymer.

Description

ELEMENT CHAUFFANT, PROCEDE DE FABRICATION ET APPLICATION HEATING ELEMENT, MANUFACTURING METHOD AND APPLICATION
La présente invention concerne un nouvel élément de chauffage électrique en forme de film ou feuille mince à structure feuilletée comprenant au moins une couche conductrice de l'électricité et au moins un substrat.The present invention relates to a new electric heating element in the form of a film or thin sheet with a laminated structure comprising at least one electrically conductive layer and at least one substrate.
Des éléments de chauffage électrique utilisés dans les applications ménagères telles que fers à repasser, grils etc.. sont formés de fils de résistance noyés dans un matériau céramique isolant, lui-même placé dans une enveloppe métallique. Un inconvénient de ce type d'élément de chauffage électrique est son inertie thermique. Un autre inconvénient est qu'il ne se prête pas à des contours complexes.Electric heating elements used in household applications such as irons, grills, etc. are formed of resistance wires embedded in an insulating ceramic material, itself placed in a metallic envelope. One drawback of this type of electric heating element is its thermal inertia. Another disadvantage is that it does not lend itself to complex contours.
En outre son épaisseur est importante et les ustensiles qui l'utilisent sont volumineux.In addition, its thickness is important and the utensils which use it are bulky.
On connait aussi des éléments de chauffage électrique en forme de feuilles à plusieurs couches : une couche conductrice de l'électricité formée d'un film métallique fin, collé sur un substrat par l'intermédiaire d'une couche adhésive hot-melt devant résister à la chaleur. Des couches hot-melt convenables sont des films extrudes d'épaisseur généralement supérieure à 20 μm.Electric heating elements in the form of sheets with several layers are also known: an electrically conductive layer formed of a thin metallic film, bonded to a substrate by means of a hot-melt adhesive layer which must resist the heat. Suitable hot-melt layers are extruded films with a thickness generally greater than 20 μm.
Un inconvénient de cet élément chauffant est la faible conductivité du film hot-melt. Cette faible conductivité ne peut en outre être améliorée sensiblement par l'incorporation de charges conductrices de la chaleur dans la couche extrudée.One drawback of this heating element is the low conductivity of the hot-melt film. This low conductivity can also not be improved appreciably by the incorporation of heat conducting charges in the extruded layer.
L'invention obvie aux inconvénients cités. Elle propose un élément chauffant en forme de film mince, à faible inertie thermique et dont la fabrication est simplifiée.The invention overcomes the disadvantages mentioned. It offers a heating element in the form of a thin film, with low thermal inertia and the manufacture of which is simplified.
L'élément chauffant selon l'invention comprend au moins un substrat et au moins une couche de résistance électrique adhérant au substrat par un liant formé à partir d'une dispersion ou solution ou poudre déposée directement sur le substrat.The heating element according to the invention comprises at least one substrate and at least one layer of electrical resistance adhering to the substrate by a binder formed from a dispersion or solution or powder deposited directly on the substrate.
Le liant selon l'invention peut être choisi parmi des dispersions ou des solutions ou des poudres d'au moins un polymère (ou copolymère), dont la température de fusion est supérieure à la température de fonctionnement de l'élément chauffant et qui peuvent être déposés sur un substrat, le cas échéant sous une faible épaisseur. De préférence, le polymère est choisi parmi les polymères perfluorés, notamment le perfluoro-alkoxy-alcane (PFA), le MFA, le polytétrafluoroéthylène (PTFE).The binder according to the invention can be chosen from dispersions or solutions or powders of at least one polymer (or copolymer), the melting point of which is higher than the operating temperature of the heating element and which can be deposited on a substrate, if necessary under a thin thickness. Preferably, the polymer is chosen from perfluorinated polymers, in particular perfluoro-alkoxy-alkane (PFA), MFA, polytetrafluoroethylene (PTFE).
Sous un aspect de l'invention, on choisit une dispersion ou solution d'au moins un des polymères cités ci-dessus et qui peut être fortement chargée le cas échéant par des charges conductrices de la chaleur et isolant électriquement, par exemple l'oxyde d'aluminium AI2O3, le carbure de silicium SiC, le mica, la poudre de verre.In one aspect of the invention, a dispersion or solution is chosen of at least one of the polymers mentioned above and which can be heavily charged if necessary by heat conducting charges and electrically insulating, for example oxide aluminum AI 2 O 3 , silicon carbide SiC, mica, glass powder.
Le substrat selon l'invention qui a notamment une fonction mécanique de support pour l'élément chauffant, ainsi qu'une fonction d'isolant électrique, peut être toute feuille sélectionnée selon l'application envisagée pour l'élément chauffant. Cette feuille peut être à base d'une matière thermoplastique ou thermodurcissable ou d'une matière cellulosique, ou un tissu ou voile de verre imprégné ou non, à base de fibres céramiques, ou encore une feuille extrudée ou déroulée. La matière thermoplastique ou thermodurcissable est choisie notamment parmi le polytétrafluoroéthylène (PTFE), le perfluoro-alkoxy-alcane (PFA), le MFA, le perfluoro (éthylène-propylène) (FEP), l'éthylène- tétrafluoroéthylène (ETFE), le fluorure de poly(vinylidène) (PVDF), le polyéthylène téréphtalate (PET), le polyimide (KAPTON). Le substrat présente une épaisseur généralement comprise entre 20 //m et 500 μm ou plus le cas échéant, selon l'application. Selon une forme de réalisation de l'invention, la couche de résistance électrique est un film ou une feuille mince d'un matériau conducteur de l'électricité, notamment à base d'un métal tel du cuivre, du nickel, de l'aluminium ou d'un alliage de métaux tel le bronze, le laiton, le Constantan R. En vue notamment d'améliorer l'adhésion de la feuille mince conductrice métallique, celle-ci peut présenter sur au moins une de ses deux faces une surface structurée obtenue par exemple par laminage dans une calandreuse munie de rouleaux à surface structurée ou une surface rugueuse obtenue par exemple par un sablage ou un traitement abrasif. La feuille métallique conductrice peut en variante être remplacée par un tissu conducteur de l'électricité ou par une couche formée d'un tapis de fibres conductrices de l'électricité.The substrate according to the invention which has in particular a mechanical support function for the heating element, as well as an electric insulator function, can be any sheet selected according to the application envisaged for the heating element. This sheet may be based on a thermoplastic or thermosetting material or on a cellulosic material, or a fabric or veil of glass impregnated or not, based on ceramic fibers, or an extruded or unwound sheet. The thermoplastic or thermosetting material is chosen in particular from polytetrafluoroethylene (PTFE), perfluoro-alkoxy-alkane (PFA), MFA, perfluoro (ethylene-propylene) (FEP), ethylene-tetrafluoroethylene (ETFE), fluoride poly (vinylidene) (PVDF), polyethylene terephthalate (PET), polyimide (KAPTON). The substrate generally has a thickness of between 20 μm and 500 μm or more if necessary, depending on the application. According to one embodiment of the invention, the electrical resistance layer is a film or a thin sheet of an electrically conductive material, in particular based on a metal such as copper, nickel, aluminum or an alloy of metals such as bronze, brass, Constantan R. With a view in particular to improving the adhesion of the metallic conductive thin sheet, this can have on at least one of its two faces a structured surface obtained for example by rolling in a calendering machine provided with rollers with structured surface or a rough surface obtained for example by sandblasting or abrasive treatment. The conductive metal sheet can alternatively be replaced by an electrically conductive fabric or by a layer formed by a carpet of electrically conductive fibers.
L'épaisseur du film mince conducteur peut être calculée selon le conducteur et l'application envisagée pour l'élément chauffant, c'est-à-dire selon la puissance électrique désirée.The thickness of the conductive thin film can be calculated according to the conductor and the application envisaged for the heating element, that is to say according to the desired electrical power.
Selon l'application le film conducteur peut avoir la forme d'un circuit en serpentin. Une telle forme s'obtient par exemple à partir d'un film continu que l'on traite par endroits par gravure chimique, à l'aide notamment d'un mélange d'acide chlorhydrique et d'eau oxygénée. Selon une variante de l'invention, la résistance électrique est obtenue directement avec la forme désirée par dépôt sur le substrat d'une composition électriquement conductrice, par exemple par sérigraphie, par pulvérisation électrostatique avec utilisation d'un pochoir, etc..Depending on the application, the conductive film can have the form of a serpentine circuit. Such a form is obtained for example from a continuous film which is treated in places by chemical etching, using in particular a mixture of hydrochloric acid and hydrogen peroxide. According to a variant of the invention, the electrical resistance is obtained directly with the desired shape by depositing on the substrate an electrically conductive composition, for example by screen printing, by electrostatic spraying with the use of a stencil, etc.
Selon une autre variante de l'invention, la couche de résistance électrique se confond avec la couche de liant qui à cette fin est chargée fortement en particules sous forme de poudre ou fibres de matériau électriquement conducteur, par exemple des particules métalliques ou des particules revêtues de métal, ou encore en graphite.According to another variant of the invention, the electrical resistance layer merges with the binder layer which for this purpose is heavily loaded with particles in the form of powder or fibers of electrically conductive material, for example metallic particles or coated particles of metal, or even graphite.
L'élément chauffant selon l'invention comprend généralement en outre un revêtement isolant électrique recouvrant la couche de résistance électrique. Ce revêtement est par exemple un second substrat du type du premier substrat décrit précédemment, pouvant adhérer sur la couche de résistance électrique par l'intermédiaire d'une autre couche adhésive.The heating element according to the invention generally also comprises an electrical insulating coating covering the electrical resistance layer. This coating is for example a second substrate of the type of the first substrate described above, which can adhere to the electrical resistance layer via another adhesive layer.
La composition de l'élément chauffant à partir de couches minces lui procure une épaisseur faible, ce qui se traduit par une inertie thermique très réduite.The composition of the heating element from thin layers gives it a low thickness, which results in a very reduced thermal inertia.
L'invention concerne aussi un procédé pour la fabrication de l'élément chauffant. Dans ce procédé, le substrat, le liant et la couche électriquement conductrices utilisés sont choisis parmi les produits décrits précédemment.The invention also relates to a method for manufacturing the heating element. In this process, the substrate, the binder and the electrically conductive layer used are chosen from the products described above.
Le procédé utilise les étapes suivantes : - on prépare le substrat devant servir de support, au moins intermédiaire, pour la réalisation de l'élément chauffant,The method uses the following steps: - the substrate to be used as a support, at least intermediate, is prepared for the production of the heating element,
- sur le substrat on dépose le liant à partir d'une dispersion ou solution ou une poudre de ce liant,- the binder is deposited on the substrate from a dispersion or solution or a powder of this binder,
- après séchage éventuel, on assemble par pressage par exemple par pressage entre les plateaux d'une presse ou par calandrage entre des rouleaux, la couche conductrice qui se présente notamment sous la forme d'un film métallique, avec le substrat revêtu du liant,after optional drying, the conductive layer, which is in particular in the form of a metallic film, is assembled by pressing, for example by pressing between the plates of a press or by calendering between rollers, with the substrate coated with the binder,
- on traite chimiquement la couche conductrice, notamment par une gravure chimique, afin de donner à cette couche la forme désirée pour la résistance électrique,the conductive layer is chemically treated, in particular by chemical etching, in order to give this layer the desired shape for the electrical resistance,
- on obtient un élément prélaminé,- a prelaminated element is obtained,
- on assemble par pressage un second substrat revêtu d'une couche de liant avec l'élément prélaminé en plaçant la couche de liant du second substrat en contact avec la couche conductrice, - on obtient finalement l'élément chauffant à structure feuilletée, de faible épaisseur et à faible inertie thermique.- a second substrate coated with a binder layer is assembled by pressing with the prelaminated element by placing the binder layer of the second substrate in contact with the conductive layer, - finally the heating element with a laminated structure, of low thickness and low thermal inertia.
L'utilisation d'une solution ou dispersion de liant permet d'obtenir des couches fines et, néanmoins, une très bonne adhésion entre les éléments du feuilleté, et qui se conserve dans le temps et dans les conditions d'usage les plus extrêmes.The use of a binder solution or dispersion makes it possible to obtain thin layers and, nevertheless, very good adhesion between the elements of the laminate, and which is preserved over time and under the most extreme conditions of use.
Lorsque l'élément chauffant utilise en tant que couche de résistance électrique chauffante une résistance obtenue par dépôt direct d'une composition conductrice par sérigraphie ou pulvérisation utilisant un pochoir, le procédé de fabrication utilise les opérations suivantes :When the heating element uses as a layer of electric heating resistance a resistance obtained by direct deposition of a conductive composition by screen printing or spraying using a stencil, the manufacturing process uses the following operations:
- on dépose sur le substrat préparé à l'aide d'un écran de sérigraphie ou d'un pochoir la composition conductrice de l'électricité, - on sèche la couche déposée,- the electrically conductive composition is deposited on the prepared substrate using a screen printing screen or a stencil, - the deposited layer is dried,
- on assemble par pressage un second substrat revêtu d'une couche de liant avec le substrat revêtu de la résistance chauffante. La résistance électrique est finalement enrobée dans la couche de liant du second substrat.- A second substrate coated with a layer of binder is assembled by pressing with the substrate coated with the heating resistor. The electrical resistance is finally embedded in the binder layer of the second substrate.
Lorsque l'élément chauffant utilise en tant que couche de résistance électrique chauffante une couche obtenue à partir de particules conductrices dispersées dans le liant, le procédé de fabrication peut alors utiliser les opérations suivantes :When the heating element uses as a layer of electric heating resistance a layer obtained from conductive particles dispersed in the binder, the manufacturing process can then use the following operations:
- on dépose sur le substrat préparé une dispersion du liant et des particules conductrices de l'électricité, - après séchage éventuel de la couche déposée, on traite chimiquement cette couche contenant les particules métalliques de manière à lui donner la forme désirée pour la résistance électrique,- a dispersion of the binder and electrically conductive particles is deposited on the prepared substrate, - after optional drying of the deposited layer, this layer containing the metallic particles is chemically treated so as to give it the desired shape for the electrical resistance ,
- on assemble par pressage un second substrat revêtu d'une couche de liant avec le substrat revêtu de la résistance électrique préparé précédemment. D'autres caractéristiques et avantages de l'invention apparaîtront dans les exemples suivants décrits en relation avec les figures.- A second substrate coated with a layer of binder is assembled by pressing with the substrate coated with the electrical resistance previously prepared. Other characteristics and advantages of the invention will appear in the following examples described in relation to the figures.
La figure 1 représente les différents stades de la fabrication d'un exemple d'un élément chauffant selon l'invention utilisant un film métallique en tant que résistance électrique chauffante. La figure 2 représente les différents stades de la fabrication d'un exemple d'un élément chauffant selon l'invention utilisant une couche à base de particules métalliques en tant que résistance électrique chauffante.FIG. 1 represents the different stages of the manufacture of an example of a heating element according to the invention using a metal film as an electric heating resistance. FIG. 2 represents the various stages of the manufacture of an example of a heating element according to the invention using a layer based on metallic particles as an electric heating resistance.
Les figures 3 et 4 représentent un élément chauffant selon l'invention muni d'un thermostat. La figure 5 représente une application pour des éléments chauffants selon l'invention. Sur la figure 1 , le substrat 1 servant de support est une feuille formée à partir d'un tissu de verre imprégné de PTFE de 80 μm d'épaisseur. Sur ce substrat, on dépose par la technique d'enduction à l'aide d'une racle ou d'un crayon, une couche 2 de PFA en dispersion dans l'eau. Après séchage à une température de 350°C, on obtient une couche deFigures 3 and 4 show a heating element according to the invention provided with a thermostat. FIG. 5 represents an application for heating elements according to the invention. In FIG. 1, the substrate 1 serving as a support is a sheet formed from a glass fabric impregnated with PTFE 80 μm thick. On this substrate, a coating 2 of PFA dispersed in water is deposited by the coating technique using a doctor blade or a pencil. After drying at a temperature of 350 ° C., a layer of
10 μm d'épaisseur environ.10 μm thick approximately.
Sur cette couche 3 on dépose une feuille métallique 4 de 50 μm d'épaisseur en Constantan et on assemble ces éléments par pressage entre les plateaux d'une presse, sous une pression de 40 bars à 350°C durant quelques minutes.On this layer 3 a metal sheet 4 50 μm thick is deposited in Constantan and these elements are assembled by pressing between the plates of a press, under a pressure of 40 bars at 350 ° C. for a few minutes.
Après avoir protégé par un vernis déposé par sérigraphie les parties de la feuille métallique destinées à former la résistance électrique, on traite l'assemblage avec un mélange d'acide chlorhydrique et d'eau oxygénée afin d'obtenir la forme désirée pour la résistance chauffante par gravure chimique. On obtient un élément prélaminé 5. On assemble ensuite par pressage dans les mêmes conditions que précédemment un second substrat 6 revêtu d'une couche de liant 7, obtenu comme dans le cas du précédent substrat revêtu, avec l'élément prélaminé 5.After having protected with a varnish deposited by screen printing the parts of the metal sheet intended to form the electrical resistance, the assembly is treated with a mixture of hydrochloric acid and hydrogen peroxide in order to obtain the desired shape for the heating resistance by chemical etching. A prelaminated element 5 is obtained. A second substrate 6 coated with a layer of binder 7, obtained as in the case of the previous coated substrate, is then assembled by pressing under the same conditions as above, with the prelaminated element 5.
On obtient finalement un élément chauffant mince 8 que l'on peut découper aux dimensions désirées et pouvant être utilisé dans diverses applications. En variante, la découpe peut être réalisée au niveau de l'élément préfabriqué, le revêtement par le second substrat s'opérant sur les éléments préfabriqués découpés.A thin heating element 8 is finally obtained which can be cut to the desired dimensions and which can be used in various applications. As a variant, the cutting can be carried out at the level of the prefabricated element, the coating with the second substrate taking place on the precast elements cut out.
Sur la figure 2, le substrat 9 servant de support peut être le même que celui décrit en relation avec la figure 1 .In FIG. 2, the substrate 9 serving as a support can be the same as that described in relation to FIG. 1.
Sur ce substrat à base de PTFE, on dépose par enduction une dispersion 10 contenant du PFA et des particules métalliques conductrices de l'électricité.A dispersion 10 containing PFA and electrically conductive metal particles is deposited on this PTFE-based substrate.
La teneur en particules métalliques est déterminée de manière à avoir un contact électrique continu dans la couche de revêtement 1 1 formée sur le substrat après séchage. Cette teneur dépend notamment des dimensions et de la forme des particules métalliques. On procède ensuite à la gravure chimique de la couche de revêtement conductrice 1 1 et on obtient un élément prélaminé 1 2.The content of metal particles is determined so as to have a continuous electrical contact in the coating layer 11 formed on the substrate after drying. This content depends in particular on the dimensions and the shape of the metallic particles. Then the chemical etching of the conductive coating layer 1 1 is carried out and a prelaminated element 1 2 is obtained.
On assemble ensuite cet élément prélaminé 1 2 avec un second substrat 1 3 revêtu dans cet exemple de la couche 14 de liant à base de PFA. On obtient un élément chauffant mince 1 5 qui peut être découpé aux dimensions désirées. En variante, la découpe s'opère au niveau des éléments préfabriqués (prélaminés).This prelaminated element 1 2 is then assembled with a second substrate 1 3 coated in this example with the layer 14 of binder based on PFA. A thin heating element 15 is obtained which can be cut to the desired dimensions. Alternatively, the cutting takes place at the prefabricated elements (prelaminated).
L'élément chauffant selon l'invention peut être utilisé aussi bien dans des applications ménagères que dans des applications industrielles qui nécessitent l'utilisation d'éléments chauffants de faible épaisseur et de faible inertie thermique. Plusieurs éléments chauffants peuvent être utilisés en combinaison.The heating element according to the invention can be used both in household applications and in industrial applications which require the use of heating elements of small thickness and low thermal inertia. Several heating elements can be used in combination.
L'élément chauffant peut aussi être utilisé avec avantage dans des milieux agressifs tels que des bains de traitement. L'élément chauffant peut être plus ou moins flexible selon les couches conductrices et les applications envisagées.The heating element can also be used with advantage in aggressive environments such as treatment baths. The heating element can be more or less flexible depending on the conductive layers and the applications envisaged.
L'élément chauffant peut être utilisé sous une forme plane ou thermoformée notamment lorsqu'il s'agit de le rigidifier. Il peut encore être utilisé grâce à sa fine épaisseur sous forme de ruban enroulé par exemple autour de tubes. Il peut aussi éventuellement être pourvu d'une couche adhésive de manière à assurer la liaison avec l'objet à chauffer.The heating element can be used in a flat or thermoformed form, especially when it comes to stiffening it. It can still be used thanks to its thin thickness in the form of a ribbon wound for example around tubes. It can also optionally be provided with an adhesive layer so as to ensure the connection with the object to be heated.
L'élément chauffant selon l'invention peut aussi être muni d'un thermostat en forme de thermocouple plat placé dans une couche adhésive adjacente à un substrat. Une réalisation d'un tel élément chauffant est représentée schématiquement sur les figures 3 et 4. Cet élément chauffant 1 6 comprend un premier substrat 1 7, une couche adhésive 1 8 contenant la résistance chauffante 1 9, un second substrat 20, une seconde couche adhésive 21 contenant un thermocouple 22 et un troisième substrat 23. La proximité du thermocouple 22 de la résistance chauffante permet une régulation très rapide de la température.The heating element according to the invention can also be provided with a thermostat in the form of a flat thermocouple placed in an adhesive layer adjacent to a substrate. An embodiment of such a heating element is shown schematically in Figures 3 and 4. This heating element 1 6 comprises a first substrate 1 7, an adhesive layer 1 8 containing the heating resistor 1 9, a second substrate 20, a second layer adhesive 21 containing a thermocouple 22 and a third substrate 23. The proximity of the thermocouple 22 of the heating resistor allows very rapid temperature regulation.
Sur la figure 5 est représentée une application qui utilise plusieurs éléments chauffants selon l'invention. Ainsi, trois éléments chauffants 24, 25, 26 sont disposés dans la semelle 27 d'un fer à repasser. Ces trois éléments chauffants peuvent présenter la même résistivité électrique ou en variante des résistivités différentes constantes ou variables en fonction de la température. Chaque élément chauffant correspond à une zone de chauffage qui peut le cas échéant être contrôlée séparément par un thermostat ou en variante par la couche résistante elle-même. Cette disposition en combinaison permet un très bon contrôle de la température de la semelle quelque soit finalement la méthode de repassage utilisée. In Figure 5 is shown an application which uses several heating elements according to the invention. Thus, three heating elements 24, 25, 26 are arranged in the sole 27 of an iron. These three heating elements can have the same electrical resistivity or, alternatively, different constant or variable resistivities depending on the temperature. Each heating element corresponds to a heating zone which can if necessary be controlled separately by a thermostat or alternatively by the resistive layer itself. This arrangement in combination allows very good control of the temperature of the sole regardless of the ironing method used.

Claims

REVENDICATIONS
1 . Elément chauffant (8 ; 1 5 ; 1 6) de faible épaisseur, caractérisé en ce qu'il comprend au moins un substrat (1 , 6 ; 9, 1 3 ; 1 7, 20, 23) et au moins une couche de résistance électrique (4 ; 1 1 ; 1 9) adhérant au substrat par un liant (3 ; 1 1 ; 1 8, 21 ) formé à partir d'une dispersion, solution ou poudre d'au moins un polymère dont la température de fusion est supérieure à la température de fonctionnement de l'élément chauffant et qui peut être déposé sur le substrat en couche mince.1. Heating element (8; 1 5; 1 6) of small thickness, characterized in that it comprises at least one substrate (1, 6; 9, 1 3; 1 7, 20, 23) and at least one resistance layer electrical (4; 1 1; 1 9) adhering to the substrate by a binder (3; 1 1; 1 8, 21) formed from a dispersion, solution or powder of at least one polymer whose melting point is higher than the operating temperature of the heating element and which can be deposited on the substrate in a thin layer.
2. Elément chauffant selon la revendication 1 , caractérisé en ce que le liant est à base d'un polymère perfluoré.2. Heating element according to claim 1, characterized in that the binder is based on a perfluorinated polymer.
3. Elément chauffant selon la revendication 2, caractérisé en ce que le polymère perfluoré est choisi parmi le PFA, le MFA, le PTFE.3. Heating element according to claim 2, characterized in that the perfluorinated polymer is chosen from PFA, MFA, PTFE.
4. Elément chauffant selon une des revendications 1 à 3, caractérisé en ce que le substrat est un voile ou tissu imprégné d'un polymère perfluoré. 4. Heating element according to one of claims 1 to 3, characterized in that the substrate is a veil or fabric impregnated with a perfluorinated polymer.
5. Elément chauffant selon la revendication 4, caractérisé en ce que le polymère perfluoré est du PTFE.5. Heating element according to claim 4, characterized in that the perfluorinated polymer is PTFE.
6. Elément chauffant selon une des revendications 1 à 5, caractérisé en ce que la couche de résistance électrique est à base d'une feuille métallique.6. Heating element according to one of claims 1 to 5, characterized in that the electrical resistance layer is based on a metal sheet.
7. Elément chauffant selon une des revendications 1 à 5, caractérisé en ce que la couche de résistance électrique est à base de particules conductrice de l'électricité dispersée dans un liant.7. Heating element according to one of claims 1 to 5, characterized in that the electrical resistance layer is based on electrically conductive particles dispersed in a binder.
8. Elément chauffant selon une des revendications 1 à 5, caractérisé en ce que la couche de résistance électrique est obtenue directement avec la forme désirée par dépôt d'une composition électriquement conductrice notamment par sérigraphie.8. Heating element according to one of claims 1 to 5, characterized in that the electrical resistance layer is obtained directly with the desired shape by depositing an electrically conductive composition in particular by screen printing.
9. Elément chauffant selon une des revendications 1 à 8, caractérisé en ce qu'il est muni d'un thermostat (22).9. Heating element according to one of claims 1 to 8, characterized in that it is provided with a thermostat (22).
1 0. Procédé pour la fabrication d'un élément chauffant selon une des revendications 1 à 6, caractérisé par les étapes suivantes : - on prépare le substrat devant servir de support pour la réalisation de l'élément chauffant, - sur le substrat, on dépose le liant à partir d'une dispersion ou solution ou une poudre,1 0. A method for manufacturing a heating element according to one of claims 1 to 6, characterized by the following steps: - the substrate is prepared to serve as a support for the production of the heating element, - the binder is deposited on the substrate from a dispersion or solution or a powder,
- après séchage éventuel, on assemble par pressage la couche conductrice avec le substrat, - on traite chimiquement la couche conductrice pour lui procurer la forme désirée pour la résistance électrique,- after optional drying, the conductive layer is pressed together with the substrate, - the conductive layer is chemically treated to give it the desired shape for the electrical resistance,
- on assemble un second substrat revêtu d'une couche de liant avec le prélaminé,a second substrate is coated with a layer of binder with the prelaminate,
- on obtient l'élément chauffant à structure feuilletée. - the heating element with a laminated structure is obtained.
1 1 . Procédé pour la fabrication d'un élément chauffant selon la revendication 7, caractérisé en ce qu'on dépose sur un substrat une dispersion du liant et des particules conductrices de l'électricité :1 1. Process for the manufacture of a heating element according to claim 7, characterized in that a dispersion of the binder and of the electrically conductive particles is deposited on a substrate:
- on traite chimiquement la couche conductrice de manière à lui donner la forme désirée, - on assemble par laminage un second substrat revêtu d'une couche de liant avec le substrat précédent.- the conductive layer is chemically treated so as to give it the desired shape, - a second substrate coated with a layer of binder is assembled by rolling with the preceding substrate.
12. Procédé pour la fabrication d'un élément chauffant selon la revendication 8, caractérisé en ce qu'on dépose sur un substrat une composition conductrice, notamment par sérigraphie, et on assemble par pressage un second substrat revêtu d'une couche de liant avec le substrat précédent.12. A method for manufacturing a heating element according to claim 8, characterized in that a conductive composition is deposited on a substrate, in particular by screen printing, and a second substrate coated with a layer of binder is pressed together the previous substrate.
1 3. Application de l'élément chauffant selon une des revendications 1 à 9 à un article ménager.1 3. Application of the heating element according to one of claims 1 to 9 to a household item.
14. Application de l'élément chauffant selon une des revendications 1 à 9, caractérisée en ce qu'elle utilise plusieurs éléments chauffants (24, 25, 26) en combinaison. 14. Application of the heating element according to one of claims 1 to 9, characterized in that it uses several heating elements (24, 25, 26) in combination.
EP96910147A 1995-05-04 1996-04-30 Heating element, fabrication process and application Expired - Lifetime EP0824847B1 (en)

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FR9505329 1995-05-04
FR9505329A FR2733871B1 (en) 1995-05-04 1995-05-04 HEATING ELEMENT, MANUFACTURING METHOD AND APPLICATION
PCT/IB1996/000390 WO1996035317A1 (en) 1995-05-04 1996-04-30 Heating element, fabrication process and application

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ATE337693T1 (en) 2006-09-15
JP2007115702A (en) 2007-05-10
US6054690A (en) 2000-04-25
AU5344596A (en) 1996-11-21
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DE69636473D1 (en) 2006-10-05
WO1996035317A1 (en) 1996-11-07
FR2733871A1 (en) 1996-11-08
CA2220001A1 (en) 1996-11-07
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JPH11505060A (en) 1999-05-11
FR2733871B1 (en) 1997-06-06

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