KR102184995B1 - Three dimensional shape type flexible heating product having carbon fiber and method for manufacturing the same - Google Patents

Abstract

The carbon fiber flexible heating product having a 3D shape according to the present invention,
In order to adhere closely to the 3D target product without wrinkles,
A flexible first insulating layer and a second insulating layer formed to be bent in a shape corresponding to the shape of the 3D target product;
A flexible carbon fiber sheet interposed between the curved first and second insulating layers and formed to be curved in a shape corresponding to the shape of the 3D target product; And
It has a 3D shape, characterized in that it includes two flexible electrodes disposed side by side on the bent flexible carbon fiber sheet and bent along the curved surface of the carbon fiber sheet.

Description

A carbon fiber flexible heating product having a 3D shape and a method of manufacturing the same {THREE DIMENSIONAL SHAPE TYPE FLEXIBLE HEATING PRODUCT HAVING CARBON FIBER AND METHOD FOR MANUFACTURING THE SAME}

The present invention relates to a flexible heating product.

Recently, a planar heating element having higher thermal efficiency than an electric heater using a heating wire has been widely used as a heating product.

Generally, the planar heating element is made by coating carbon black on a PET (Polyethylene Terephthalate) film.

When such a planar heating element is bent, the PET film is bent and cut, so that cracks may occur between the carbon black formed on the PET film and may be disconnected. This leads to defective heating products.

In order to solve this problem, a flexible heating product of the present applicant is disclosed in a registered patent (10-1867394).

The applicant's flexible heating product includes: a flexible first insulating layer; A flexible second insulating layer; A flexible carbon fiber sheet interposed between the first insulating layer and the second insulating layer, and a flexible electrode attached to the carbon fiber sheet, and the carbon fiber sheet is composed of carbon fibers randomly arranged to overlap each other, a cushion It can be easily installed on products that can be wrinkled, such as chair sheets, bed sheets, and gloves.

Due to the superiority of such a flexible heating product, many inquiries have recently been made to the applicant of the present applicant, asking whether it is possible to install a flexible heating product even on a target product having a complex three-dimensional shape such as a car steering wheel, a car door trim, and a car armrest.

However, no matter how flexible the flexible heating product is, if the flat flexible heating product is forcibly bent to match the flexible heating product to the target product with a complex three-dimensional shape, wrinkles are formed throughout the flexible heating product. There is no other choice but to cause the phenomenon of excitement without being in close contact.

The present invention was created after research and development to solve this problem.

Korean registered patent (10-1867394)

An object of the present invention is to provide a carbon fiber flexible heating product having a 3D shape and a method of manufacturing the same, which can be adhered to a target product having a complex 3D shape without wrinkles.

Carbon fiber flexible heating products having a 3D shape to achieve the above object,

To adhere closely to the 3D target product without wrinkles,

A flexible first insulating layer and a second insulating layer formed to be bent in a shape corresponding to the shape of the 3D target product;

A flexible carbon fiber sheet interposed between the curved first and second insulating layers and formed to be curved in a shape corresponding to the shape of the 3D target product; And

It is characterized in that it comprises a flexible electrode arranged side by side on the flexible carbon fiber sheet formed to be bent, bent along a curved surface of the carbon fiber sheet.

In addition, the above purpose,

A first step of preparing a mold having a shape corresponding to the shape of the 3D target product;

Put a flat and flexible first insulating layer in the mold, put a flat and flexible carbon fiber sheet on the flat and flexible first insulating layer, and flat and flexible electrodes on the flat and flexible carbon fiber sheet A second step of covering the flat and flexible second insulating layer on the flat and flexible carbon fiber sheet to cover the flat and flexible electrodes arranged side by side at a predetermined interval and spaced side by side at a predetermined interval;

The flat and flexible first insulating layer, the flat and flexible carbon fiber sheet, and flat and flexible electrodes disposed side by side at a predetermined interval on the flat and flexible carbon fiber sheet, and the flat and flexible material 2 a third step of forming a molded article by pressing and heating the insulating layer all at once in a mold to form the shape of the 3D target product; And

It is achieved by a carbon fiber flexible heating product manufacturing method having a 3D shape, characterized in that it comprises a fourth step of taking out the molded product from the mold.

In the present invention, since the heating product itself has a curved shape corresponding to the target product having a complex three-dimensional shape, there is no need to forcibly bend the flat flexible heating product to fit the flexible heating product with the target product having a complex three-dimensional shape. As a result, it is possible to prevent the flexible heating product from being wrinkled in the process of bending the flat and flexible heating product, thereby preventing the flexible heating product and the target product from being in close contact and being lifted.

In the present invention, a heat insulating material or a reflective material is further attached to the surface of the second insulating layer in direct contact with the target product, thereby blocking or reflecting heat going toward the target product through the first insulating layer. It increases thermal efficiency by directing heat toward people located on the outside of the product. In addition, the insulating material or reflector is made of a hard material to maintain the 3D shape of the flexible heating product for a long time.

In the process of making the present invention into a shape corresponding to a target product having a three-dimensional shape in a mold, a certain part may be narrowed and certain parts may be widened due to pressure and heating. As a result, heat is generated in a place where the gap between the electrodes is narrowed, and heat is reduced in a place where the gap between the electrodes is wide. In order to eliminate such an imbalance in the amount of heat generated, less resistance holes are drilled in places where the spacing between electrodes is narrower than in places where the spacing between electrodes is widened. Since the resistance around the resistance hole is higher than that of the non-resistance hole, heat is generated, so by adjusting the number and spacing of the resistance hole, the disparity in the amount of heat generated due to the gap between the electrodes can be eliminated.

The present invention makes a molded product by pressing and heating a flexible first insulating layer, a flexible carbon fiber sheet, a flexible electrode, and a second flexible insulating layer, so that a carbon fiber flexible heating product having a 3D shape is produced. It can be easily created.

1 is a view showing a state in which a carbon fiber flexible heating product having a 3D shape is installed on a steering wheel of a car having a 3D shape according to an embodiment of the present invention.
2 is a view showing a state in which a carbon fiber flexible heating product having a 3D shape is installed in a car door trim having a 3D shape according to an embodiment of the present invention.
3 is a view showing a state in which a carbon fiber flexible heating product having a 3D shape according to an embodiment of the present invention is installed on an automobile armrest having a 3D shape.
FIG. 4 is a diagram illustrating a cross section IV-IV shown in FIG. 1.
5 is a view showing a state in which a resistance hole penetrating a carbon fiber flexible heating product having a 3D shape is drilled between two electrodes.
6 is a view showing a state in which an insulating material is further attached to the rear surface of the second insulating layer shown in FIG. 4 according to the first modified example.
FIG. 7 is a diagram illustrating a state in which a reflector is further attached to the rear surface of the second insulating layer shown in FIG. 4 according to the second modified example.
8 is a flow chart showing a method of manufacturing a carbon fiber flexible heating product having a 3D shape according to an embodiment of the present invention.

Hereinafter, a carbon fiber flexible heating product having a 3D shape according to an embodiment of the present invention will be described.

As shown in FIG. 1, a carbon fiber flexible heating product 10 having a 3D shape is installed on a steering wheel 1 having a 3D shape. As shown in FIG. 2, a carbon fiber flexible heating product 10' having a 3D shape is installed on an automobile door trim 2 having a 3D shape. As shown in FIG. 3, a carbon fiber flexible heating element 10" having a 3D shape is installed on an automobile armrest 3 having a 3D shape.

Of course, carbon fiber flexible heating products (10,10',10") having a 3D shape can be installed anywhere with a three-dimensional shape other than the car handle (1), car door trim (2), and car armrest (3). Is possible.

Hereinafter, the present invention will be described with a carbon fiber flexible heat generating product 10 having a 3D shape installed on a steering wheel 1 having a 3D shape.

As shown in FIG. 4, the carbon fiber flexible heating product 10 having a 3D shape includes a first insulating layer 11, a second insulating layer 12, a carbon fiber sheet 13, and electrodes 14. Consists of Reference numeral T denotes a portion cut to fit the carbon fiber flexible heating product 10 having a 3D shape into the handle body 1a.

The carbon fiber flexible heating product 10 is attached to the handle body 1a with an adhesive H. To this end, the adhesive (H) is applied to the surface of the first insulating layer 11 in direct contact with the handle body (1a).

The first insulating layer 11 and the second insulating layer 12 are formed to be curved in a shape corresponding to the shape of the 3D target product. Here, the meaning of “formed to be curved” is a concept that is formed only with a curved surface or includes both a flat surface and a curved surface. It is the same below.

The first insulating layer 11 and the second insulating layer 12 are flexible. The first insulating layer 11 and the second insulating layer 12 have both an insulating function and a waterproof function.

To this end, the first insulating layer 11 and the second insulating layer 12 are made of a polymer material or rubber to a thickness of 0.1 to 0.5 mm.

If necessary, a coating layer may be further attached to the surface of the second insulating layer 12 that is touched by a person. The covering layer can be made variously of fabric, leather, artificial fur, fur, etc. The second insulating layer 12 may be painted without a coating layer to give the feeling of the coating layer.

The carbon fiber sheet 13 is interposed between the flexible first insulating layer 11 and the second insulating layer 12 formed to be curved, and is formed to be curved in a shape corresponding to the shape of the 3D target product.

The carbon fiber sheet 13 is flexible. To this end, the carbon fiber sheet 13 is made to a thickness of 0.1 ~ 0.5mm.

The carbon fiber sheet 13 is composed of carbon fibers that are randomly arranged to overlap each other.

On the other hand, when the flat carbon fiber sheet 13 is molded, the amount of carbon fibers in the bent portion is scattered around, and the amount of carbon fibers in the non-bent portion is maintained as it is. Accordingly, the amount of heat generated by the final 3D carbon fiber flexible heating product 10 may be different in the curved portion and the flat portion. In order to prevent this, the amount of carbon fibers in the portion to be bent during molding in the flat carbon fiber sheet 13 is greater than the amount of carbon fibers in the portion not to be bent during molding. As a result, carbon fibers are scattered around in the bent portion during molding, and the amount of carbon fibers in the curved and flat portions of the final 3D carbon fiber flexible heating product 10 becomes the same, and the final 3D carbon fiber flexible heating product 10 The calorific value may be the same in any part.

The electrodes 14 are arranged side by side on the flexible carbon fiber sheet 13 formed to be bent, and are bent along the curved surface of the carbon fiber sheet 13.

The electrodes 14 are composed of a first electrode 14a, a second electrode 14b, a third electrode 14c, and a fourth electrode 14d. The first electrode 14a, the second electrode 14b, the third electrode 14c, and the fourth electrode 14d are disposed at intervals of 90 degrees. Of course, the number and arrangement of electrodes may vary.

The first electrode 14a and the second electrode 14b are arranged side by side on the flexible carbon fiber sheet 13 formed to be bent, and are bent along the curved surface of the carbon fiber sheet 13. To this end, each of the first electrode 14a and the second electrode 14b is made of copper having a thickness of 0.1 to 0.5 mm. The first electrode 14a is connected to the + pole of the power supply (not shown), and the second electrode 14b is connected to the-pole of the power supply (not shown).

The third electrode 14c and the fourth electrode 14d are arranged side by side on the flexible carbon fiber sheet 13 formed to be bent, and are bent along the curved surface of the carbon fiber sheet 13. To this end, each of the third electrode 14c and the fourth electrode 14d is made of copper having a thickness of 0.1 to 0.5 mm. The third electrode 14c is connected to the + pole of the power supply (not shown), and the fourth electrode 14d is connected to the-pole of the power supply (not shown).

The power supply unit (not shown) is located in the vehicle. The power supply unit (not shown) and the first electrode 14a, second electrode 14b, third electrode 14c, and fourth electrode 14d are connected by wires (not shown). The electric wire (not shown) passes through the handle body 1a.

The current supplied from the power supply unit (not shown) is supplied to the first electrode 14a, the second electrode 14b, the third electrode 14c, and the fourth electrode 14d to flow through the carbon fiber sheet 13. Heat is generated from the carbon fiber sheet 13, which is a resistor, and the carbon fiber flexible heating product 10 having a 3D shape is warmed.

Meanwhile, as shown in FIG. 5, a resistance hole 15 may be drilled between electrodes 14a and 14b having different intervals.

The reason why the spacing L1 between the electrodes 14a and 14b is different is that the electrodes 14a and 14b are arranged side by side and spaced apart in the mold in the process of pressing and heating in order to make the shape corresponding to the target product having a three-dimensional shape ( This is because the gap between 14a and 14b) narrows in some parts and widens in some parts.

The reason for drilling the resistance hole 15 is as follows. Where the distance between the electrodes 14a and 14b is narrow, the current flows more because the distance between the electrodes 14a and 14b is close, so that the carbon fiber sheet 13 heat generation amount increases, and the electrodes 14a and 14b In a place where the gap between the electrodes 14a and 14b is wide, the electric current flows less because the distance between the electrodes 14a and 14b is wide, so that the amount of heat generated by the carbon fiber sheet 13 is decreased. Due to this, a difference in calorific value occurs. However, when the resistance hole 15 is drilled, the resistance around the resistance hole 15 becomes higher, so that the amount of heat generated is greater than that where the resistance hole 15 does not exist. Accordingly, by adjusting the number of resistance holes and the distance L2 between the resistance holes, an imbalance in the amount of heat generated due to the difference in the distance between the electrodes 14a and 14b can be eliminated.

For example, as shown in FIG. 5, the regions B and D in which the spacing between the electrodes 14a and 14b is narrower than those in the regions A and C in which the spacing between the electrodes 14a and 14b is relatively wide. Drill less resistance holes 15. In addition, even within the same area, less resistance holes 15 are drilled in places where the distance between the electrodes 14a and 14b is narrow.

Modification 1

As shown in Figure 6, the carbon fiber flexible heating product 20 having a 3D shape according to the first modified example, a first insulating layer 21, a second insulating layer 22, a carbon fiber sheet 23 , Electrodes 24, and an insulating material 25. The electrodes 24 are composed of a first electrode 24a, a second electrode 24b, a third electrode 24c, and a fourth electrode 24d. The carbon fiber flexible heating product 20 is attached to the handle body 1a with an adhesive H. Reference numeral T denotes a portion cut to fit the carbon fiber flexible heating product 20 having a 3D shape into the handle body 1a.

The carbon fiber flexible heating product 20 having a 3D shape according to the first modified example is the same except for the carbon fiber flexible heating product 10 and the heat insulating material 25. Therefore, description of the remaining components except for the insulating material 25 will be omitted.

The insulating material 25 is attached to the surface of the first insulating layer 21 in direct contact with the 3D target product and is formed to be bent in a shape corresponding to the shape of the 3D target product. The insulating material 25 blocks heat going toward the handle body 1a through the first insulating layer 21 so that it is directed toward the person holding the handle body 1a.

The insulating material 25 is made of non-woven fabric. Alternatively, if the insulating material 25 is made of a hard material (such as PET), the 3D shape of the 3D flexible heating product 10 may be maintained for a long time.

2nd modified example

As shown in FIG. 7, the carbon fiber flexible heating product 30 having a 3D shape according to the second modified example includes a first insulating layer 31, a second insulating layer 32, and a carbon fiber sheet 33. , Electrodes 34, and a reflector 35. The electrodes 34 are composed of a first electrode 34a, a second electrode 34b, a third electrode 34c, and a fourth electrode 34d. The carbon fiber flexible heating product 30 is attached to the handle body 1a with an adhesive H. Reference numeral T denotes a portion cut to fit the carbon fiber flexible heating product 30 having a 3D shape to the handle body 1a.

The carbon fiber flexible heating product 30 having a 3D shape according to the second modified example is the same except for the carbon fiber flexible heating product 10 and the reflector 35. Therefore, description of the remaining components except for the reflector 35 will be omitted.

The reflector 35 is attached to the surface of the first insulating layer 31 in direct contact with the target product, and is formed to be bent in a shape corresponding to the shape of the 3D target product. The reflector 35 blocks heat going toward the handle body 1a through the first insulating layer 31 so that it is directed toward the person holding the handle body 1a.

The reflector 35 is made of silver foil. Alternatively, if the reflector 35 is made of a hard material, the 3D shape of the 3D flexible heating product 10 can be maintained for a long time.

Hereinafter, a method of manufacturing a carbon fiber flexible heating product having a 3D shape according to an embodiment of the present invention will be described.

As shown in Figure 8, the carbon fiber flexible heating product manufacturing method having a 3D shape according to an embodiment of the present invention,

A first step (S11) of preparing a mold having a shape corresponding to the shape of the 3D target product;

Put a flat and flexible first insulating layer in the mold, put a flat and flexible carbon fiber sheet on the flat and flexible first insulating layer, and flat and flexible electrodes on the flat and flexible carbon fiber sheet A second step (S12) of covering the flat and flexible second insulating layer on the flat and flexible carbon fiber sheet to cover the flat and flexible electrodes arranged side by side at a predetermined interval and spaced side by side at a predetermined interval;

The flat and flexible first insulating layer, the flat and flexible carbon fiber sheet, and flat and flexible electrodes disposed side by side at a predetermined interval on the flat and flexible carbon fiber sheet, and the flat and flexible material A third step (S13) of forming a molded article by pressing and heating the two insulating layers in a mold at one time to shape the 3D target product;

It consists of a fourth step (S14) of taking out the molded product from the mold.

Hereinafter, the first step (S11) will be described.

Prepare a mold with a shape corresponding to the shape of the 3D target product. The shape of the mold may vary depending on the shape of the 3D target product. In addition, the mold method may also be various such as a pressure heating method, an injection method, and a drawing method.

Hereinafter, the second step (S12) will be described.

Put a flat and flexible first insulating layer in the mold. A flat and flexible carbon fiber sheet is placed on the flat and flexible first insulating layer. Flat and flexible electrodes are placed side by side at regular intervals on a flat and flexible carbon fiber sheet. A flat and flexible second insulating layer is covered on the flat and flexible carbon fiber sheet so as to cover the flat and flexible electrodes arranged side by side at regular intervals.

Hereinafter, the third step (S13) will be described.

A flat and flexible first insulating layer, a flat and flexible carbon fiber sheet, flat and flexible electrodes arranged at regular intervals side by side on a flat and flexible carbon fiber sheet, and a flat and flexible second insulating layer are provided. By pressing and heating all at once in a mold, it is molded into the shape of a 3D target product to make a molded product.

Hereinafter, the fourth step (S14) will be described.

The molded article is removed from the mold.

On the other hand, after the fourth step (S14), as shown in FIG. 5, a fifth step (S15) of drilling a resistance hole 15 between the electrodes 14a and 14b having different intervals may be further included. .

The reason why the spacing between the electrodes 14a and 14b is different and the reason why the resistance hole 15 is drilled between the electrodes 14a and 14b having different spacings are as described above.

10,10',10": carbon fiber flexible heating product with 3D shape
11,21,31: first insulating layer 12,22,32: second insulating layer
13,23,33: carbon fiber sheet 14,24,34: electrodes
15: resistance hole 25: insulating layer
35: reflective layer H: adhesive

Claims (5)

A flexible first insulating layer and a second insulating layer formed to be bent in a shape corresponding to the shape of the 3D target product so as to adhere to the 3D target product without wrinkles;
A flexible carbon fiber sheet interposed between the curved first and second insulating layers and formed to be curved in a shape corresponding to the shape of the 3D target product;
Flexible electrodes disposed side by side on the flexible carbon fiber sheet formed to be bent, and bent along a curved surface of the carbon fiber sheet; And
It includes a resistance hole drilled between the electrodes,
Where the spacing between the electrodes is narrow, the current flows more because the distance between the electrodes is close, so that the amount of heat generated by the carbon fiber sheet increases, and where the spacing between the electrodes is wide, the distance between the electrodes is long. Therefore, the amount of heat generated by the carbon fiber sheet in that part is small due to low current flow.
When the resistance hole is drilled in the carbon fiber sheet, the resistance is higher around the resistance hole, so that the amount of heat generated is greater than that of the non-resistance hole,
A region with a narrow gap between the electrodes has fewer resistance holes than a region with a relatively wide gap between the electrodes, and even within the same region, fewer resistance holes are drilled where the gap between the electrodes is narrow,
Carbon fiber flexible heating product having a 3D shape, characterized in that to solve the imbalance of the heating value due to the difference in the gap between the electrodes. The method of claim 1,
A carbon fiber flexible heating product having a 3D shape, characterized in that it is attached to the surface of the first insulating layer in direct contact with the 3D target product, and further comprises an insulating material formed to be bent in a shape corresponding to the shape of the 3D target product. The method of claim 1,
A carbon fiber flexible heating product having a 3D shape, characterized in that it is attached to the surface of the first insulating layer in direct contact with the 3D target product, and further comprises a reflector formed to be bent in a shape corresponding to the shape of the 3D target product. delete delete

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