Self-regulating electric heating element for heaters shaped as cartridges or test tubes

Abstract: Self-regulating electric heating element formed by a resistance made of composite material, having a cylindrical or prismatic outer shape which can be inserted in a cartridge or a cavity of the article to be heated. It is schematically composed of an assembly of self-regulating electric conductors (PTC) made of composite material of polymeric matrix (resistive conductors) constituting the resistive portion providing for heat generation by Joule effect, a powered electrode system which distributes the electric current to said resistive portion and a core made of insulating material, which supports and keeps into position both the resistive conductors and the electrode system.

Description: The present invention relates to an electric heating element namely a self-regulating joule-effect heating body having a cylindric or prismatic outer form which can be inserted mainly but non exclusively in a cartridge or a test tube. From US-A-4.379.220 is known an electric resistance heating element to be inserted in a housing for heating water of aquariums, having low energy density and made by conductive polymeric heaters, mesh metal heaters with a busbar at parallel edges, and thin film evaporative heaters formed by evaporating metal on plastic substrate, such a heating element comprising one or more conductors connected to the mains supply by a system of one or more electrodes formed by metallic materials connected to the supply cables, and comprising a circuit protection device connected in series to the heating element, formed by at least two electrodes and a PTC element composed of a PTC composition, having high positive temperature coefficient at the operation temperatures. This heating element also comprises a wedge-shaped core made of insulating material onto which the conductors and the electrodes are applied, which core is introduced in the corresponding shaped housing, and maintained with its heating conductors in a good thermal coupling with the housing so as to heat this latter, with consequent heating of water of the aquarium. From WO-A.9.531.882 is known a compact immersion heater for water of aquariums, composed of an electric resistance heating element to be inserted in a housing, and comprising one or more conductors connected to the mains supply by a system of one or more electrodes formed by metallic materials connected to the supply cables, wherein the conductors are made of a laminar structure formed by a layer of an electrically resistive material that is anchored to a core of insulating material, wherein the resistive material is a PTC ink with high positive temperature coefficient at the operating temperatures, that is printed onto the core in selected regions that are connected to the electrodes. From EP-A-0198.598 is known an electrical device containing PTC conductive polymers of polymeric matrix with resistive function, an electric conductive filler and a possible non-conductive filler, which are formulated with such a ratio and materials as to achieve an electric resistance with high positive temperature coefficient at the operating temperatures. The present invention relates to an electric resistance heating element as defined in claim 1. A single embodiment of the invention will be represented by the following description, with reference to the attached drawings, wherein : Fig. 1 shows an exploded perspective view of a not-limiting embodiment of the present heating element ; Fig. 2 and 2a show a front and a plan view of the heating element of Fig. 1 ; Fig. 3 shows the electric wiring diagram of the heating element of Fig. 1 ; Fig. 4 shows the electric wiring diagram of a heating element similar to that one of Fig. 1 ; Fig. 5 shows the typical behaviour of the electric resistivity on the volume ratio of conductive particles of a composite material with polymeric binder and filler formed by conductive particles; Fig. 6 shows the resistance change on the temperature (PTC effect) of an electric conductor formed by a composite material with polymeric binder and filler formed by conductive particles at a suitable ratio thereof ; Fig. 7 a shows a cutaway view of an element similar to that one of Fig. 1, in which however the core is made in a manner different; Figs 7 b, 7 c and 7 d show the element of Fig. 7 a in three different operating modes thereof; Fig. 7 e shows a component part of the element of Fig. 7 a ; Fig. 8 shows a possible arrangement of two elements as illustrated by the Figs. 7 a - 7e. With reference to Figs. 1 and 2, a heating element 1 having cylindrical body with resistive conductors 2 made of composite material with PTC characteristics and extended in a longitudinal direction is provided, which heating element is arranged on a core 3 provided with a single longitudinal hole 4 for the passage of a supply cable and a longitudinal slot 5, permitting a metallic resilient element 6 to be inserted therein for being expanded. The core 3 is provided with longitudinal slots 7 for housing the resistive conductors 8 and two slots 9 and 10 at its outer periphery for housing the two electrodes 11 and 12, which are made preferably as an open annular metallic foil for permitting the heating element expansion, and which are disposed outside the resistive conductors 8 and connected to the supply conductors 13 and 14. The resistive conductors 8 are constituted by a suitable conductive composite material with self-regulating characteristics, and particularly by an electric conductive filler e.g. one or more conductive powders such as carbon black, graphite, silver etc., by the polymeric binder e.g. one or more polymers such as polyethylene, polyamides, thermoplastic polyesters, acetal resins, PEEK, PES, PPS etc., and by possible additional additives and/or not-conductive fillers providing for special physical-chemical characteristics of the so obtained composite material such as plasticizers, inert fillers, lubricants, stabilizers etc. It is known that a composite material formed by a polymer and micrometric particles of electric conductive material which are closely mixed together has a resistivity value which decreases with the volume ratio of the electric conductive particles, and which shows a strongly positive TCR (temperature coefficient of the resistance) at a particular range of the composition of the composite materials the so-called percolation range. By disregarding the physical aspects which are known from the theory which explain the manifestation of a remarkable PTC effect, is is evident that by employing different materials such as binders e.g. polymers, electric conductive fillers e.g. particles, and percentages of filled particles it is possible to obtain composite materials having electric resistivity, temperature coefficient (PTC) and thermal-physical characteristics which can be defined in advance. The resistive conductors made of the so formulated composite material at a certain temperature present a high output reduction due to a high resistance increases, which fact provides for self-regulating of temperature of the heating element. The Table 1 describes two not-limiting examples of materials suitable for this purpose. It is evident that also different combinations of materials according to the described principles and and mixtures of the so formulated composite materials can be employed for the most different uses. Examples of formulation of composite materials for the resistive conductors. Example N. 1 : material with self-regulating characteristics. Composition HD Polyethylene (High Density Polyethylene) 65 % volume, Carbon black powder 28 % volume, wherein this main conductive filler is formed by Carbon black powder of RCF-type with middle BET (surface area) and low particle size used in the zone 18 of the diagram of Fig. 5, referred to the system formed by the present HD-PE e carbon black, Graphite powder 7 % volume, wherein this filler is a secondary conductive filler formed by graphite with average granulometry of 4 µm, whose function is to increase the conductivity and improve the heat flow of the composite material, Titanium dioxide 1% volume. Example N. 2 : material with zero temperature coefficient (No PTC effect) Composition Thermoplastic polyester 69 % volume, Carbon black powder 27 % volume, which is the main conductive filler formed by Carbon black powder of RCF type with conductive grade, with low absorption, middle BET (surface area) and low particle size used in the zone 20 of the diagram of Fig. 5, Carbon black pellets 2,5 % volume, which is a secondary conductive filler formed by Carbon black pellets of RCF type (extra conductive grade), high absorption, high BET (surface area) and middle particle size. The resistive conductors are obtained by submitting the described material to the conventional forming processes of the plastic materials, namely extrusion, injection molding, thermoforming etc... Such conductors can be realized directly onto the core of the heating element or also separately as strips or shaped with other forms, which are subsequently assembled onto the core by means of glueing, heat seal, or simply by applying a mechanical pressure between the core and the envelope where the element must be disposed. The resistive conductors can be made with constant or anyhow variable cross-section. A variable cross-section may permit to attain a differentiated heating or a most wide contact with the electrodes. The different resistive conductors may be separated or each one of them can be joined to a-nother one by means of bonds of the same material, so as to form a single body made preferably by injection molding and preferably open along a generating line, thereby permitting a limited expansion of the resulting sleeve. The resistive part of composite material can be made on an embodiment thereof with a single conductor, which provides for a sleeve, preferably open longitudinally along a generating line, of resistive material arranged around the core. The conductors with resistive function made of composite material are powered by two or more electrodes, whose number, arrangement, location and type may vary. The electrodes may be made of metallic material shaped as foils, plaits, wires, cables, by utilizing any other material having a good electric conductivity such as included electroconductive composite materials, electroconductive paints or inks, metallized parts. A possible constructive solution is also the direct use of the supply cables as electrodes. Whatever the electrodes are made, the contact with the resistive conductors can be obtained indifferently outside and inside e.g. electrodes embedded on the resistive conductors or electrodes arranged between the core and the resistive conductors. The conductors with resistive function and the electrodes are located onto a core of insulating material. As not-limitative examples of materials with which the core may be made are : polymers and elastomers with different amounts and types of fillers, ceramic, glass. Generally, any material or combination of insulating materials may be employed. The core is provided at its outer surface with slots providing for housing the conductors with resistive function and the associated electrodes. The slots serve for housing the composite conductors and centering the core in the course of the manufacturing process, in particular when the composite conductors are applied, which fact however does not exclude that the composite conductors can be arranged simply onto the insulating core unprovided with slots. The shape of the entire heating element and therefore of the core forming the base thereof may be cylindrical, as commonly for the heaters shaped as cartridges or test tubes it is the case, or prismatic with any polygonal cross-section. The core central portion may be provided with one or more longitudinal through holes and/or cavities (not indicated) permitting one or more cables or electric conductor of other kind to pass therethrough, blind or through holes and/or cavities (not indicated) with different positions for housing some sensors, safety devices, regulating devices or the like. In accordance to another characteristic of the invention, the core may be made, by exploiting the elasticity of its constructive material, such as for example a siliconic elastomer, and/or by employing some additional rigid or resilient mechanical elements 6 such as for example a longitudinal metallic spring which is inserted in a proper slit provided along the entire core lenght, in such a way as to be forced radially therein once the heating element is introduced in the test tube, cartridge or other suitable seat, thereby causing the thermal contact resistance between the heating element, which in a suitable case is wound on a film or an insulating paper or the like, and the wall of the envelope into which it is contained to be minimized. As already stated, the heating element conductive portion is formed by a portion formed by a plurality of conductors with resistive function and made of composite material devoted to heat generation, and a portion connected to an electric supply and made typically but not exclusively of metallic material. The electric connection between these two portions may be realized in different manners. Schematically, such arrangements can be the following : axial current flow in the resistive portion and electrodes with circumferential extent, circumferential current flow in the resistive portion and electrodes with longitudinal extent, combination of the two previous cases with current flow with an axial and a circumferential component (as for example a resistive portion forming a helical path with steady or variable pitch). Such connection is made evident by the Fig. 3, showing the electric wiring diagram of the electrodes and the resistive conductors of the heating element of Figs. 1 and 2, and the Fig. 4 showing the electric wiring diagram of the electrodes and the resistive conductors of a heating element similar to that one of Fig. 1, in which however a third intermediate electrode 15 is connected. Such an arrangement may be supplied with DC or monophase AC so as to permit to decrease the resistance of the element connected thereto, in particular of the zones A and B, the two extreme electrodes 16 and 17 are connected to each other, and to obtain an element with more power levels by means of a selector (not indicated) permitting the zones A and B to be supplied in series, in parallel or separately to each other. A differentiated output of the zones A and B may be obtained by arranging the intermediate electrode 15 at a not central position thereof and connecting in parallel the two zones A and B. The present heating element, as the other heating elements used at the present inside test tubes or cartridges, may occupy either the entire space available in the envelope or a part thereof only, in the case in which an accurate temperature adjustment device, for example a bimetallic thermostat, an electronic thermostat and/or a safety system, for example a fuse, must be inserted therein. One of these adjustment or safety components may be inserted also inside the insulating core, into specific cavities thereof as already explained. The present heating element may be completed also with other component parts performing auxiliary functions. The heating element according to the invention is insulated electrically, when it is inserted in a metallic cartridge or a metallic seat, with the interposition of a polymeric dielectric film, an insulating paper or other electric barrier. The same type of electric barrier is applied on the test tubes when a double wall insulation is required. With reference to the Fig. 5, shown therein is the typical behaviour of the electric resistivity on the volume ratio of conductive particles of a composite material with polymeric binder and filler formed by conductive particles. In order to achieve the PTC effect, a filler percentage on the zone 18, i.e. percolation zone, must be chosen. A very low electric conductivity is achieved on the zone 19, while a high electric conductivity with practically no temperature coefficient is achieved on the zone 20. With reference to Fig. 6, shown therein is the resistance change on the temperature of an electric conductor formed by a composite material with polymeric binder and filler formed by conductive particles at a suitable ratio thereof (see zone 18 of Fig. 5). Such heating element may be used in combination with heating test tubes for aquarium apparatuses, test tubes for heating photographic or chemical baths, cartridges for all uses with middle-low specific power (output/cartridge surface) and the like. Turning now to the Figs. 7 a - 7 e, showing a core of the present element made in another manner, it is represented a core 3 made of elastomer material, which is unprovided with slots for housing the resistive conductors, but it is provided with some peripheral and radially protruded ribs 21, which are orthogonal to the electric current flow, whose height is almost equal to the thickness of the resistive conductors 2, which during the assembling of the conductors on the core are squashed inward by the pressure of the envelope against the resistive conductors, from the position of Fig. 7 b to the position of Fig. 7 c. In case of an overheating of the resistive conductors, these latter soften and melt, so that the ribs 21 expand against the resistive conductors (see Fig. 7 d), and therefore, by means of this mechanical action, increase the electrical resistance thereof and improve the operating safety of the assembly. Fig. 7 e shows the resistive conductors of the element of Fig. 7 a, in this case formed by four conductors, which are made integrally and connected to each other by some bonds 22 of the same material, except the first and the last conductors, so as to permit a limited expansion of the assembly. Finally, Fig. 8 shows two identical modular shaped elements of the kind referred to, which can be coupled inside the same envelope (for example, a test tube), so as to attain an output which is multiple than that of a single module. In this case, an inner wiring permitting the needed parallel connection thereof is shown. In this way, modules which are identical may be utilized for each envelope, e.g. cartridges or test tubes, for different output ranges, as in the case of heaters for aquariums. The advantages offered by the present invention can be summarized as follows: the heating element according to the invention has a monolithic construction with respect to the current elements, permitting a quick and simple introduction thereof in the test tube or cartridge and therefore an easy automatic assembling thereof. An intrinsic power and therefore temperature self-limitative capacity of the heating element, due to the considerable positive temperature coefficient (PTC) of the resistance, deriving from the special composite material utilized for the resistive portion. The utilized conductive composite material may be so formulated as to achieve volume resistivity, PTC curve and max. temperature of use which are variable on a wide range. The heating element referred to may be manufactured by exploiting simple and proven technologies which are widely used for manufacturing products made of plastic materials. The manufacturing simplicity of the present heating element insures a low scattering of the resistance values with respect to other PTC resistances used at the present. The thermal resistance between the heat generating area (conductors made of resistive composite materials) and the envelope (test tube, cartridge or the like) is minimized, since the heat generating area is situated on the heating element surface, which fact involves limited thermal heads and therefore outputs at low temperature levels on the resistive portion. In the case in which the core is made of an elastomer material, a mechanical system for increasing the electrical resistance of the resistive conductors can be provided, so as to improve the safe operation of the present element.

Claims: Electric resistance heating element, preferably of cylindrical or prismatic shape, to be inserted in test tubes, cartridges or other housing comprising one or more resistive conductors (2,8) connected to the means supply by a system of two or more electrodes (11,12), said conductors (2,8) being made of conductive composite material of polymer matrix with resistive function, which are formed at such ratio and materials as to achieve an electric resistance with high positive temperature coefficient (PCT) at the operation temperatures, said conductors (2,8) and said electrodes (11,12) being applied on at least a core (3) made of insulating materials, said composite material being constituted by a mixture of a polymeric binder, preferably a thermoplastic material, an electric conductive filler and a possible additional additive constituted by a not-conductive filler providing for special physical-chemical characteristics of such mixture, said polymeric binder being constituted by one or more polymers, said conductive filler being constituted by a conductive powder in the form of micrometric particles, wich has a resistivity value decreasing with the volume ratio of said conductive powder and showing a strongly positive temperature coefficient of resistance at a particular range of the composite material and. said electrodes (11,12) being formed by metallic materials such as foils, plaits, conductive coating layers such as inks, paints and the like, characterized in that said resistive conductors (2,8) are shaped as strips or with other forms extended in a longitudinal direction of said core, and realized separateby and introduced into slots(7) provided on the outer surface of said core(3), or realized directby onto said core(3), said conductors (2,8) being connected electrically with said electrodes (11,12) with such an arrangement as to realize an axial current flow in the conductors (2,8)with electrodes(11,12) with circumferential extent, or a circumferential current flow in the conductors(2,8) with electrodes(11,12) with longitudinal extent, or a combination of the current flow with an axial and a circumferential component with a helical path of said conductors(2,8), and said core(3) is provided with a single longitudinal hole (4) running along the central longitudinal axis of said core (3), for the passage of a supply cable and a longitudinal slit (5) provided along the entire core length for the insertion of a resilient element (6) in said slit (5) for expanding the same core. Electric resistance heating element according to claim 1, characterized in that said resistive conductors (2, 8) may be obtained with one of the conventional forming processes of the polymeric materials (plastics). Electric resistance heating element according to the preceding claims, characterized in that said core (3) is made of elastomer material and provided with peripheral and radially protruded ribs (21), which are orthogonal to the electric current flow, whose height is almost equal to the thickness of said conductors (2, 8), which during the assembling of said conductors (2, 8) on the core (3) are squashed inwardly by the pressure of the housing against said resistive conductors (2, 8), so as in case of overheating of said conductors (2, 8) these latter soft and melt and said ribs (21) expand against said conductors (2, 8). Heating element according to claim 5, characterized in that there are used modular shaped elements combined together, so as to attain different output ranges. Heating element according to the preceding claims, characterized in that it may be inserted into its housing by interposing one dielectric film or more dielectric films or other insulating material.

Inventors: CARLET ENNIO, CARLET, ENNIO
Applicants: CARLET ENNIO, CARLET, ENNIO
Application year: 1997
Main classification: H05B3
IPC codes: H05B3