DE102014116311A1 - Areal resistive heating element with at least one heating layer and method of manufacture - Google Patents

Abstract

The object of the invention is to provide a sheet-like resistance heating element and a method for its production, which can be produced with little effort on thin flat or spatial surfaces or shapes reliable and also individually dimensioned, it requires no additional support structures in the heating layer and for any flat and spatial arrangements of the heating element can be used.
The planar resistance heating element according to the invention with at least one heating layer (1) consists of a compound which is composed of - about 20-35% of a rubber, - about 20-35% tetrahydro-furan, - about 5-25% graphite and - about 20-35% of a polyurethane,
wherein the heating layer is applied directly on a non-structural basis on at least one side of a geometrically arbitrary surface (2) or on the surface of any geometric shape (3) of a (known per se) plastic, plastic composite or other electrically insulating material and with contacts (4 ) is provided.
The inventive method for producing the planar resistance heating elements provides that on one side of a first planar, electrically insulating substrate made of plastic a compound is applied as a heating layer immediately without additional carrier or stabilizer surface, dried and cured and that on and / or be applied under the heating layer contacts.
The field of application of the invention lies in the production of heating arrangements of any structure and spatial extent for spatial structures, for areas in rooms and on any traffic routes.

Description

The invention relates to a sheet-like resistance heating element with at least one heating layer and a method for its production, in particular for the production of geometrically flat and spatial heating surfaces.

Flat heating elements can be known to produce by means of prepreg plates, between which a heating layer is arranged. The problem here is that the heating layers used have a textile support structure. In particular, the placement of the heating layer on or between the prepreg layers high demands are made to avoid shifting or overlapping by turning the textile support structure within the prepreg layers. In addition, when using heating layers on textile or non-woven base bends and radii for the production of spatial arrangements can be realized only limited, since these structures would tear mechanically overstressed, whereby the heating layer would assume at least partially undefined states. The heating layer can be too thick, too thin or mutually superimposed by the mechanical stresses. This can result in uneven current distributions, resulting in different surface temperatures, especially too high temperatures. The heating layer can be damaged by the overlay. A homogeneous and reliable heating would therefore no longer be possible.

In Scripture DE 10 2006 012 647 B4 is z. Example, a heating with a heating layer between prepreg layers is described, wherein the heating layer is sandwiched in the prepreg layer of a high-resistance prepreg material and the heating layer is a Heizvlies whose surface is completely covered by the prepreg layer.

The problem here is that the heating layer has a textile structure and thus must be produced in an own technological process and adapted for use. Individual and short-term adjustments of the heating layer during the production of the heating element are not possible.

The object of the invention is to provide a sheet-like resistance heating element and a method for its production, which can be produced with little effort on thin flat or spatial surfaces or shapes reliably and also individually dimensioned, while no additional support structures are needed in the heating layer and thereby any planar and spatial arrangements of the heating element can be used.

With the invention is achieved in the specified application, that a sheet-like resistance heating element with at least one heating layer and a method for its production are created. The planar resistance heating element consists of at least one heating layer which consists of a compound, wherein the compound is proportionally composed of rubber, tetrahydro-furan, graphite and polyurethane. The liquid to pasty compound is applied directly, so for example without a textile support structure, on at least one side of a geometrically arbitrary surface or on the surface of any geometric shape of an electrically insulating material and provided with contacts.

The invention provides a sheet-like resistance heating element with at least one heating layer. The heating layer is a plastic-based substance mixture which can be applied as a so-called compound without its own support structure, such as a textile fabric, on at least one side of a geometrically arbitrary surface or on the surface of any geometric shape.

• – ca. 20–35 % eines Kautschuks,
• – ca. 20–35 % Tetrahydro-Furan,
• – ca. 5–25 % Graphit und
• – ca. 20–35 % eines Polyurethans.

The compound consists of:

• - about 20-35% of a rubber,
• - about 20-35% tetrahydro furan,
• - about 5-25% graphite and
• - About 20-35% of a polyurethane.

The substrate or the geometric shape to which the heating layer compound can be applied can therefore be any plastic, a plastic composite or another electrically insulating material. For example, the heating layer compound may be applied to a prepreg semi-finished product, which is then processed into a plastic composite. The compound is correspondingly provided with contacts for connection to an electrical voltage source.

The heating surface coating according to the invention can be applied to surfaces of different materials with arbitrary shapes. In this respect, the heating surface is universally applicable.

The heating layer can be applied both on the entire surface or surface of a geometric shape as well as on partial surfaces thereof.

According to an advantageous embodiment of the invention according to claim 2, the flat surface or the geometric shape 3 are flexible and / or elastic. Thus, as support materials for the Heizflächenbeschichtung films, Planes, silicone body and film-like, plastic-coated fabric as well as other flexible materials are used.

According to a development of the invention according to claim 3, a further planar substrate is arranged on the respective side of the sheet-like substrate with the heating layer or applied an electrically insulating cover layer. The two flat surfaces are pressed into a composite, welded, laminated or glued.

Accordingly, flat structures can be created with the invention, which can be used for example as a radiator or in which a heating function can be integrated.

According to a development of the invention according to claim 4, the further planar surface also on at least on the first surface facing surface side also has a carrierless heating layer with or without contacts on. Accordingly, surface heating elements can be realized with two heating surfaces. Thus, the deliverable heating power can be increased.

According to a development of the invention according to claim 5, the contacts are guided accordingly by an opening in the surface of the sheet-like substrate or the geometric shape and / or laterally to the respective boundary edges of the sheet surface or the geometric shape to the outside. Due to the different feedthroughs of the contacts for connection to an electrical power supply, the heating surfaces can be used in many ways. The contact or cable guide is flexibly adaptable to different applications.

• – ca. 20–35 % eines Kautschuks,
• – ca. 20–35 % Tetrahydro-Furan,
• – ca. 5–25 % Graphit und
• – ca. 20–35 % eines Polyurethans,

als Heizschicht auf mindestens einer Seite eines flächigen Untergrundes oder auf der Oberfläche einer beliebigen geometrischen Form aus einem Kunststoff, Kunststoffverbund oder einem anderen elektrisch nicht leitenden Material. Das Compound wird unmittelbar, also ohne integrierte Trägerstruktur, wie beispielsweise ein textiles Gewebe, aufgetragen, getrocknet und ausgehärtet. Weiterhin werden auf, unter und/oder in die Heizschicht Kontaktierungen aufgebracht. Das Compound kann dabei auf die gesamte Fläche beziehungsweise Oberfläche eines geometrischen Körpers oder auf eine oder mehrere Teilflächen davon aufgetragen werden. Bei einem vollflächigen Auftrag des Compound lassen sich so beispielsweise Flächenheizkörper herstellen. The inventive method for producing the planar heating elements according to the independent claim 6 comprises the surface application of a compound consisting of

• - about 20-35% of a rubber,
• - about 20-35% tetrahydro furan,
• - about 5-25% graphite and
• - about 20-35% of a polyurethane,

as a heating layer on at least one side of a flat surface or on the surface of any geometric shape of a plastic, plastic composite or other electrically non-conductive material. The compound is applied directly, ie without integrated support structure, such as a textile fabric, dried and cured. Furthermore, contacts are applied to, under and / or into the heating layer. The compound can be applied to the entire surface or surface of a geometric body or to one or more partial surfaces thereof. In the case of a full-surface application of the compound, surface heating elements can be produced, for example.

According to a development of the method for producing the heating element according to claim 7, a further planar substrate is arranged on the respective side of the sheet surface above the applied heating layer and pressed into a composite according to a known method, welded, laminated or glued. Thus, for example, when using prepreg semifinished products, a plastic composite with integrated heating layer can be produced.

According to one embodiment of the invention according to claim 8 is also applied to the other flat surface, at least on the first planar surface facing side, also a carrierless heating layer and dried or cured. If the flat substrate consists of prepreg semifinished products, then a plastic composite material with heating function can be realized. In accordance with the requirements and the desired results, the pressing pressure for pressing, welding, laminating or gluing the flat substrates to a composite can be set to this variable.

A development of the invention according to claim 9, the heating layer is applied twice or more times, wherein the respective underlying heating layers are dried and cured before the application of the overlying layer. By repeated repetition of the coating with the compound larger layer thicknesses of the heating surfaces can be realized. This makes it possible to realize the heating elements for larger electrical connection values and thus for corresponding larger heating outputs.

A development of the method according to claim 10, the heating layers are applied by rolling, brushing, printing, knife coating or spraying. Due to its consistency and the required carrier material, the heating surface compound offers different possibilities of application to the surfaces. This can, depending on the application, different, respectively advantageous coating technologies are used.

According to a development according to claim 11, the heating layer is coated on the surface of the geometric shape by suitable methods known per se and with a suitable per se known electrically insulating cover layer. By finishing with an insulating cover layer, the heated surfaces can also be touched, with the respective persons through the insulation will be protected. Likewise, electrical equipment is protected that could come into contact with the heating surface.

According to use claim, the planar heating elements can be used for one-, two- or three-dimensional heating surfaces in and / or on objects, in rooms and / or on traffic routes. Thus arise for the invention broad applications in which a heating surface is needed, which is reliable and can be produced with little effort. In particular, the arbitrary geometries bring advantages in any use. Several embodiments of the invention are illustrated in the drawings and will be described in more detail below.

Show it:

1 a schematic representation of a planar resistance heating element with a heating layer,

2 a schematic representation of a planar resistance heating element with a heating layer between two flat surfaces,

3 a schematic representation of a planar resistance heating element with two heating layers between two flat surfaces,

4 a schematic representation of a U-shaped geometric shape with a heating layer and an electrically insulating cover layer,

5 a schematic representation of a geometric shape of a halved cylinder ring with a heating layer and an electrically insulating cover layer,

6 a plan view of a provided with a compound heating layer, curved surface and

7 a plan view of a provided with a compound heating layer surface.

The invention relates to planar structures and surfaces of geometric body, to which a Heizflächenbeschichtung is applied from a compound. Thus, corresponding heating elements can be manufactured. According to the invention, the compound consists of about 20-35% of a rubber, about 20-35% of tetrahydro-furan, about 5-25% of graphite and about 20-35% of a polyurethane.

• – Kautschuk oder ein insbesondere mechanisch und/oder elektrisch gleich oder ähnlich wirkendes Material, mit ca. 20–35 %, vorzugsweise ungefähr 25–30 %, besonders bevorzugt etwa 24 %,
• – Tetrahydro-Furan oder ein insbesondere mechanisch und/oder elektrisch gleich oder ähnlich wirkendes Material: mit ca. 20–35 %, vorzugsweise ungefähr 25–30 %, besonders bevorzugt etwa 24 %,
• – Graphit oder ein insbesondere mechanisch und/oder elektrisch gleich oder ähnlich wirkendes Material: mit ca. 5–25 %, vorzugsweise ungefähr 10–20 %, besonders bevorzugt etwa 15 %, und
• – Polyurethan, wie beispielsweise und mit Vorzug 4715 Lupranol der Firma BASF, oder ein insbesondere mechanisch und/oder elektrisch gleich oder ähnlich wirkendes Material: mit ca. 20–35 %, vorzugsweise ungefähr 25–30 %, besonders bevorzugt etwa 26 %.

The components of the electrically conductive compound heating layer are in detail:

• A rubber or a material which acts in particular mechanically and / or electrically identically or similarly, with about 20-35%, preferably about 25-30%, particularly preferably about 24%,
• Tetrahydro-furan or a material which acts in particular mechanically and / or electrically the same or similar: with about 20-35%, preferably about 25-30%, particularly preferably about 24%,
• - Graphite or a particular mechanically and / or electrically the same or similar acting material: with about 5-25%, preferably about 10-20%, more preferably about 15%, and
• Polyurethane, such as, for example, and with preference 4715 Lupranol from BASF, or a material which in particular acts mechanically and / or electrically the same or similar: with about 20-35%, preferably about 25-30%, particularly preferably about 26%.

In 1 an inventive, areal heating element is shown. The heating element consists of a heating layer 1 bearing ground 2 , To supply with electrical energy are two spaced contacts 4 , such as sheet metal strip with the heating layer 1 , connected. The heating layer 1 is made from a compound composed of about 20-35% of a rubber, about 20-35% tetrahydro-furan, about 5-25% graphite and about 20-35% of a polyurethane. This compound heating layer 1 is a resistance heating element, which by applying a voltage to the contacts 4 Converts electrical energy into heat. The compound is mixed together from the components and onto the substrate 2 for example, applied by rolling, spraying, printing or knife coating. As a supporting ground 2 Different materials can be used. These materials do not have to be conductive or provided with an electrically insulating coating (not shown). It can, for example, prepared from prepreg semi-finished sheets as a substrate 2 be used. The conclusion forms an electrically insulating cover layer (not shown) for protection against electrical voltage.

In 2 is a sheet-like resistance heating element with a heating layer 1 between two flat surfaces 2 shown. With the compound heating layer 1 are on both sides strip-like contacts 4 connected. The areal substrates 2 can be plates made of plastic or plastic composites. The resistance heating elements can be used, for example, as area heaters for space heating.

The 3 comes from 2 out. Between two flat surfaces 2 are two compound heating layers 1 shown. Between the two heating layers 1 are the contact strips 4 arranged for energy supply. By a multiple coating and several, possibly against each other isolated compound layers, larger layer thicknesses of the heating surfaces can be realized. This makes it possible to realize the heating elements for larger electrical connection values and thus for corresponding larger heating outputs. Likewise, the heating power can be regulated accordingly.

In 4 is a U-shaped geometric shape 3 with a heating layer 1 and an electrically insulating cover layer 5 shown. The compound heating layers 1 can be applied liquid to viscous on different surfaces. This makes the compound heating layers suitable 1 for application on surfaces of any body 3 , For protection against the supply voltage is an electrically insulating cover layer 5 finally applied. The contacts 4 to be powered by the geometric shape 3 , here the U-profile, led to the outside.

Another geometric shape 3 that with a compound heating layer 1 is provided, shows 5 , Here is on the inside of the geometric shape 3 a halved cylinder ring a heating layer 1 and an electrically insulating cover layer 5 applied. The contacts 4 are here by the electrically insulating cover layer 5 led to the outside. In this way, for example, heated gutters can be realized.

6 shows in plan view a heating layer 1 , which here on an S-arc-shaped underground (not shown, corresponds to the area of underground 2 and contacts) is applied. The compound heating layer 1 is between two laterally extending contacts 4 arranged. At the top are the compound heating layer 1 and the contacts 4 provided with an electrically insulating cover layer (not shown).

In this way, for example, curved traffic routes can be heated. In an analogous manner, other three-dimensional irregular shapes or surfaces can be realized with a compound heating layer.

The 7 shows in plan view a compound heating layer 1 , which is here applied to a substrate with a partially rectangular surface (not shown). The peculiarity here is that the rectangular base consists of, for example, two parts, which are spaced from each other, wherein the two parts have a complementary, oblique transitions 6 and thus have a chamfer and thus collided with each other. At the side of the compound heating layer 1 are the contacts 6 arranged to supply electrical energy. The compound heating layer 1 and the contacts 4 are provided above with an electrically insulating cover layer (not shown). This heating element constructed in this way can be arranged, for example, on the surface of magnetic track tracks (not shown) in order to keep them free of ice, with joints to compensate for the thermally induced expansions 6 are present, which to avoid impacts on the wheels as oblique transitions 6 are available at intervals.

The figures show an example that different surfaces or surfaces of any body can be provided with a heating layer according to the invention. This refers to a broad field of application for the inventive heating elements by way of example.

LIST OF REFERENCE NUMBERS

1

heating layer

2

underground

3

geometric shape

4

contact

5

insulating cover layer

6

Push, transition

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102006012647 B4 [0003]

Claims (12)

Surface resistive heating element with at least one heating layer ( 1 ), characterized in that the heating layer ( 1 ) of a compound consisting of - about 20-35% of a rubber, - about 20-35% tetrahydro-furan, - about 5-25% graphite and - about 20-35% of a polyurethane, directly on a carrier structure at least one side of a geometrically arbitrary surface ( 2 ) or on the surface of any geometric shape ( 3 ) is applied, wherein the substrate or the form of a known plastic, plastic composite or other electrically insulating material and applied with contacts ( 4 ) is provided. Areal resistive heating element according to claim 2, characterized in that the flat surface ( 2 ) or the geometric shape ( 3 ) is flexible and / or elastic. Areal resistive heating element according to one of the preceding claims, characterized in that on the respective side of the flat surface ( 2 ) or the geometric shape ( 3 ) with the heating layer ( 1 ) another surface ( 2 ) or an electrically insulating cover layer ( 5 ) is applied and the two surface substrates ( 2 ) are pressed into a composite, welded, laminated or glued. Surface resistive heating element according to one of the preceding claims, characterized in that on the further surface ( 2 ) or the geometric shape ( 3 ) at least on the first surface ( 2 ) facing side also a carrierless heating layer ( 1 ) with or without contacts ( 4 ) is arranged. Surface resistive heating element according to one of the preceding claims, characterized in that the contacts ( 4 ) through an opening in the surface of the flat surface ( 2 ) or the geometric shape ( 3 ) and / or laterally at the respective boundary edges of the flat surface ( 2 ) or the geometric shape ( 3 ) and / or by the electrically insulating cover layer ( 5 ) are led to the outside. Method for producing the planar resistance heating elements according to claim 1 to 5, characterized by the following features: - that on at least one side of a flat surface ( 2 ) or on the surface of any geometric shape ( 3 ) of a plastic, plastic composite or other electrically non-conductive material, a compound consisting of - about 20-35% of a rubber, - about 20-35% tetrahydro-furan, - about 5-25% graphite, and - approx 20-35% of a polyurethane, for the heating layer ( 1 ) is applied as a Widerstandsheizschicht immediately without integrated support structure surface, dried and cured and - that on, under and / or in the heating layer ( 1 ) Contacts ( 4 ) to be brought. A method according to claim 6, characterized in that on the respective side of the flat surface ( 2 ) with the applied heating layer ( 1 ) another surface ( 2 ) is arranged and pressed into a composite according to a method known per se, welded, laminated or glued. Method according to one of claims 6 and 7, characterized in that on the further surface ( 2 ) at least on the first surface ( 2 ) facing side also a carrierless heating layer ( 1 ) is applied and dried and cured. Method according to one of claims 6 to 8, characterized in that the heating layer is applied twice or more times. Method according to one of claims 6 to 9, characterized in that the heating layer ( 1 ) is rolled, painted, printed, doctored or sprayed. Method according to one of claims 6 to 10, characterized in that the heating layer ( 1 ) on the surface of the geometric shape ( 3 ) according to known per se suitable methods and with a suitable per se known electrically insulating cover layer ( 5 ) is covered / coated.  Use of the heating elements according to claim 1 to 5 for one-, two- or three-dimensional (geometrically planar and geometrically spatial) heating surfaces in and / or on objects, in rooms and / or on traffic routes.

Images