Patent IE-41728-B1 (IE)
Title: Articles having a positive temperature coeficient of resistance
IPC: H01C1/14
Filed: 1975-09-24
Abstract: 1529354 Resistance heating element RAYCHEM CORP 26 Sept 1975 [27 Sept 1974 4 Aug 1975] 39517/75 Heading H5H [Also in Division H1] An electric heater comprises a first resistive layer in electrical and thermal contact with at least part of the surface of a second resistive layer, the first resistive layer having a P.T.C. of resistance and undergoing an abrupt change in resistance at its anomaly temperature, and the second layer having a substantially constant resistance, at least below the anomaly temperature of the first resistive layer. The combination of the first and second resistive layers enables the effective regulating temperature of the heater to be varied within wide limits since in use as the temperature of the heater varies so the proportion of current passed by the two resistive layers varies. The P.T.C. material used may be a ceramic or a polymeric composition, preferably cross-linked which is loaded with particulate carbon black, graphite, metal, conductive metal salts and oxides, or boron or phosphorus doped silicon or germanium. The material of the second constant resistance layer (C.W.) may be a P.T.C. material providing its anomaly point is above the anomaly temperature of the first P.T.C. material. Suitable CW materials include materials whose resistance does not increase by more than a factor of six in any 30‹ C. range below the anomaly temperature of the P.T.C. material. Suitable CW materials are thermoplastics highly loaded with carbon black or metals. The conductive particles may be spherical, lenticular or fibrillar. Other materials are carbon coated asbestos paper, metal wires supported by inorganic insulating materials. The C.W. material may be sufficiently conductive to serve as electrodes for the heater, but if it is is insufficiently conductive highly conductive filler material in the form of fibres or fibrils may be incorporated to act as electrodes. Electrodes may alternatively be formed as metal fabric mesh or grid, flexible metal strip, convoluted wires, conductive paint, solid carbon, e.g. carbon fibres, graphite impregnated fibre, metal coated fibre, e.g. copper or stainless steel or solid metal conductors. In Fig. 6, P.T.C. layer 11 is in contact with CW layer 12 and grid electrodes 13, 14 are applied to the exposed surfaces of layers 11, 12. In Fig. 7 (not shown) electrically parallel strip electrodes are embedded in the CW layer and a continuous sheet electrode is applied to the exposed surface of the P.T.C. layer. In Fig. 8 (not shown), registering parallel strip electrodes are applied between the P.T.C.and C.W. layers and to the exposed surface of the P.T.C. layer. In Fig. 12 (not shown) parallel strip electrodes are embedded in two CW layers which sandwich a P.T.C. layer, the strip electrodes of one CW layer being staggered relative to those of the other CW layer. In Fig. 13 (not shown) a disc shaped heater comprising a P.T.C. resistive layer sandwiched between two CW layers has shunt connected wire electrodes embedded in the CW layers and arranged so that they extend orthogonally. For use in forming heat recoverable encapsulating articles, e.g. cable splices, a laminate m which the layers are flexible, polymeric material with some or all heat recoverable is described. The laminate comprises an outer layer of insulating material which may or may not be heat recoverable, a C.W. layer having embedded therein parallel braided, serrated, or convoluted electrodes, a P.T.C. layer, a second C.W. layer with embedded electrodes, an insulating material layer which may be heat recoverable and a heat activatable adhesive layer. In Fig. 16, the P.T.C. layer 60 and CW layer 58 are wedge shaped as shown with strip electrodes 55, 56 applied to their exposed surfaces. In Fig. 17 (not shown) the compositions of the P.T.C. layer and CW layer are locally varied to alter the wall density and/or the effective regulating temperature. In Fig. 18 (not shown) a metal pipe to be heated forms one electrode for the heater which comprises a concentric CW layer, a concentric P.T.C. layer, a concentric CW layer and a concentric outer electrode layer. In Fig. 19 (not shown) the various layers are wrapped around the pipe and may be united by heat. In Fig. 20 a P.T.C. layer 59 surrounding one electrode 55 is embedded in a CW layer 57. Both electrodes 55 and 56 may be surrounded by a P.T.C. layer. In an alternative arrangement (Fig. 21, not shown) one electrode is embedded in a P.T.C. layer and the other in a CW layer, the layers abutting. In Fig. 23 electrodes 55, 56 are embedded in P.T.C. layer 59 which is surrounded by CW layer 57. Below the anomaly point of the P.T.C. material current flows predominantly through the P.T.C. layer 59 but above the anomaly point current predominantly follows a path which is a minimum in the P.T.C. layer 59, i.e. the current flows across the width of the layer 59 from electrode 55 to CW layer 57, along CW layer 57 to a point opposite electrode 56 and then across the width of layer 59. In a variation of this arrangement the electrodes are each in contact with both the P.T.C. and a CW layer. In Fig. 26 (not shown) the P.T.C. layer is in contact with only small portions of two CW layers which have the supply electrodes embedded therein. In Fig. 27 (not shown) a P.T.C. layer provided with an exposed electrode makes contact with only a portion of a CW layer provided with several superficial parallel electrodes. Electrode wires coated with P.T.C. material and CW material may be combined to form flat heaters. In Fig. 35, not shown, electrode wires are embedded in CW layers which sandwich a P.T.C. layer. The wires are staggered relative to one another and have insulating coatings which are interrupted lengthwise to provide axially staggered exposed conductive electrode sections. The heaters may be used for heating pipes, to form the walls of ovens, residences or vehicles, for heating vessels, for deicing roads and aircraft wings, for waterbed heaters, warming trays, frying pans, griddles and medical heating pads.