Conductive heating composition and flexible conductive heating device using the same

Abstract

A conductive heating composition includes a polyolefin elastomer, a crystalline non-grafted polyolefin, a crystalline polymer which is grafted or copolymerized with a monomeric unit, and a conductive filler. The composition has a surface resistivity ranging from 1.0E+01 ohm to 1.0E+06 ohm, and a volume resistivity ranging from 8.0E+01 ohm-cm to less than 1.0E+05 ohm-cm. When the composition is heated from 20 C. to 90 C., a log value of a resistance of the composition increases with a slope ranging from 3E02 log ohm/ C. to 9E02 log ohm/ C. After a specimen made of the composition is repeatedly bent 300 times, a surface resistance of the specimen at a room temperature increases by a rate of less than 300%.

Claims

1. A conductive heating composition comprising: a polyolefin elastomer in an amount ranging from 39 wt % to 50 wt % based on 100 wt % of a total weight of said conductive heating composition; a crystalline non-grafted polyolefin; a crystalline polymer which is grafted or copolymerized with a monomeric unit selected from carboxylic acid, carboxylic acid derivatives, and combinations thereof; and a conductive filler, wherein said conductive heating composition has a surface resistivity ranging from 1.0E+01 ohm to 1.0E+06 ohm, and a volume resistivity ranging from 8.0E+01 ohm-cm to less than 1.0E+05 ohm-cm; when said conductive heating composition is heated from 20 C. to 90 C., a log value of a resistance of said conductive heating composition increases with a slope ranging from 3E-02 to 9E-02; and after said conductive heating composition being tested according to ISO 132:1999 procedure 300 times, a surface resistance of said conductive heating composition at a room temperature increases by a rate of less than 300%.

2. The conductive heating composition according to claim 1, wherein said polyolefin elastomer has a shore A hardness ranging from 40 to 95.

3. The conductive heating composition according to claim 1, further comprising an additive selected from the group consisting of a volume filler, a flame retardant, a coupling agent, and combinations thereof.

4. The conductive heating composition according to claim 1, wherein said polyolefin elastomer is selected from the group consisting of ethylene-octene copolymer, ethylene-butene copolymer, ethylene-propylene copolymer, propylene-butene copolymer, butene-ethylene copolymer, butene-propylene copolymer, and combinations thereof.

5. The conductive heating composition according to claim 1, wherein said crystalline non-grafted polyolefin is selected from the group consisting of polyethylene, propylene, polyvinylidene fluoride, and combinations thereof.

6. The conductive heating composition according to claim 1, wherein said crystalline polymer is selected from the group consisting of ethylene vinyl acetate copolymer, ethylene butyl acrylate, ethylene methyl acrylate, ethylene acrylic acid, polyethylene grafted with ethylene-g-maleic anhydride, polyethylene grafted with ethylene-g-acrylic acid, and combinations thereof.

7. A flexible conductive heating device comprising: a flexible conductive heating substrate which is made of said conductive heating composition of claim 1, and which has a first major surface and a second major surface opposite to said first major surface in a thickness direction of said flexible conductive heating substrate; and at least one first electrode unit formed on said first major surface, and including a positive electrode including a first base portion and a plurality of first finger electrode portions which extend respectively from said first base portion, and which are arranged to be separated from each other, and a negative electrode including a second base portion which is spaced apart from said first base portion, and a plurality of second finger electrode portions which extend respectively from said second base portion, and which are arranged to be interdigitated with said first finger electrode portions, wherein two adjacent ones of said first and second finger electrode portions are spaced apart from each other by a first distance ranging from 0.5 mm to 20 mm, each of said first and second finger electrode portions being spaced apart from a respective one of said second and first base portions by a second distance, a ratio of the second distance to the first distance being larger than 0.8.

8. The flexible conductive heating device according to claim 7, further comprising at least one second electrode unit which is formed on said second major surface, and which includes a positive electrode including a first base portion and a plurality of first finger electrode portions which extend respectively from said first base portion, and which are arranged to be separated from each other, and a negative electrode including a second base portion which is spaced apart from said first base portion of said positive electrode of said second electrode unit, and a plurality of second finger electrode portions which extend respectively from said second base portion, and which are arranged to be interdigitated with said first finger electrode portions of said positive electrode of said second electrode unit, wherein each of said first finger electrode portions of said first electrode unit is overlapped with a respective one of said second finger electrode portions of said second electrode unit in the thickness direction by at least 10 percent area, and each of said second finger electrode portions of said first electrode unit is overlapped with a respective one of said first finger electrode portions of said second electrode unit in the thickness direction by at least 10 percent area.

9. The flexible conductive heating device according to claim 7, further comprising a second electrode unit which is formed on said second major surface, and which includes a positive electrode including a first base portion and a plurality of first finger electrode portions which extend respectively from said first base portion, and which are arranged to be separated from each other, and a negative electrode including a second base portion which is spaced apart from said first base portion of said positive electrode of said second electrode unit, and a plurality of second finger electrode portions which extend respectively from said second base portion, and which are arranged to be interdigitated with said first finger electrode portions of said positive electrode of said second electrode unit, wherein each of said first finger electrode portions of said first electrode unit is overlapped with a respective one of said first finger electrode portions of said second electrode unit in the thickness direction by at least 10 percent area, and each of said second finger electrode portions of said first electrode unit is overlapped with a respective one of said second finger electrode portions of said second electrode unit in the thickness direction by at least 10 percent area.

10. The flexible conductive heating device according to claim 7, wherein said first electrode unit is formed by hot pressing a metal foil on the first major surface of said flexible conductive heating substrate to form a metal layer, and patterning the metal layer to form said first electrode unit.

11. The flexible conductive heating device according to claim 7, wherein said first electrode unit is formed by screen printing a conductive paste or glue on said first major surface.

12. The flexible conductive heating device according to claim 7, wherein each of the positive and negative layers is coated with a layer made of an insulating or thermal conductive material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Other features and advantages of the disclosure will become apparent in the following detailed description of the embodiment(s) with reference to the accompanying drawings, in which:

(2) FIG. 1 is a schematic perspective view of a conventional heating element which is in a laminate form;

(3) FIG. 2 is a schematic perspective view of a conventional heating element which is in a dumbbell form;

(4) FIG. 3 is a temperature versus resistance graph for a conventional conductive polymer composite material;

(5) FIG. 4 illustrates a schematic top view of a flexible conductive heating device according to a first embodiment of the disclosure;

(6) FIG. 5 is a cross-sectional view taken along line 5-5 of FIG. 4;

(7) FIG. 6 illustrates a schematic top view of a flexible conductive heating device according to a second embodiment of the disclosure;

(8) FIG. 7 is a cross-sectional view taken along line 7-7 of FIG. 6;

(9) FIG. 8 is a cross-sectional view of a flexible conductive heating device according to a third embodiment of the disclosure;

(10) FIG. 9 illustrates a schematic top view of a flexible conductive heating device according to a fourth embodiment of the disclosure;

(11) FIG. 10 is a cross-sectional view taken along line 10-10 of FIG. 9;

(12) FIG. 11 is a temperature versus resistance graph for materials prepared in a first experiment;

(13) FIG. 12 is a temperature versus resistance graph for materials prepared in a third experiment;

(14) FIG. 13 illustrates a result of a self temperature limiting test for a composition of Example 6A (EX 6A); and

(15) FIG. 14 illustrates a result of a self current regulation test for the composition EX 6A under higher and lower ambient temperatures.

DETAILED DESCRIPTION

(16) Before the disclosure is described in greater detail, it should be noted that where considered appropriate, reference numerals have been repeated among the figures to indicate corresponding or analogous elements, which may optionally have similar characteristics.

(17) A conductive heating composition according to an embodiment of the disclosure is a positive temperature coefficient material, and includes (i) a polyolefin elastomer, (ii) a crystalline non-grafted polyolefin which is different from the polyolefin elastomer, (iii) a crystalline polymer which is grafted or copolymerized with a monomeric unit selected from carboxylic acid, carboxylic acid derivatives, and combinations thereof, and (iv) a conductive filler. The conductive heating composition has a surface resistivity ranging from 1.0E+01 ohm to 1.0E+06 ohm, and a volume resistivity ranging from 8.0E+01 ohm-cm to less than 1.0E+05 ohm-cm. When the conductive heating composition is heated from 20 C. to 90 C., a log value of a resistance of the conductive heating composition increases with a slope ranging from 3E02 to 9E02. After the conductive heating composition has been tested according to ISO 132:1999 procedure 300 times, a surface resistance of the conductive heating composition at a room temperature increases by a rate of less than 300%.

(18) In certain embodiments, the polyolefin elastomer is in an amount ranging from 5 wt % to 50 wt % based on 100 wt % of a total weight of the conductive heating composition.

(19) In certain embodiments, the polyolefin elastomer is in an amount ranging from 10 wt % to 50 wt % based on 100 wt % of a total weight of the conductive heating composition.

(20) In certain embodiments, the polyolefin elastomer is in an amount ranging from greater than 15 wt % to 50 wt % based on 100 wt % of a total weight of the conductive heating composition.

(21) In certain embodiments, the polyolefin elastomer is in an amount ranging from 39 wt % to 50 wt % based on 100 wt % of a total weight of the conductive heating composition.

(22) In certain embodiments, the polyolefin elastomer has shore A hardness value ranging from 40 to 95. Examples of the polyolefin elastomer include, but are not limited to, ethylene-octene copolymer, ethylene-butene copolymer, ethylene-propylene copolymer, propylene-butene copolymer, butene-ethylene copolymer, butene-propylene copolymer, etc.

(23) Examples of the crystalline non-grafted polyolefin include, but are not limited to, polyethylene (PE), propylene (PP), polyvinylidene fluoride (PVDF), etc.

(24) The crystalline polymer may be a crystalline grafted polymer or a crystalline copolymer. Examples of the crystalline copolymer include, but are not limited to, ethylene vinyl acetate copolymer (EVA), ethylene butyl acrylate (EBA), ethylene methyl acrylate (EMA), ethylene acrylic acid (EAA), etc. Examples of the crystalline grafted polymer include, but are not limited to, polyethylene grafted with ethylene-g-maleic anhydride, polyethylene grafted with ethylene-g-acrylic acid, etc.

(25) In certain embodiments, the conductive filler is made of inorganic carbon, metal, or a combination thereof. Examples of the inorganic carbon include, but are not limited to, carbon black, graphite, graphene, titanium carbide (TiC), tungsten carbide (WC), tungsten titanium carbide (TiWC), etc. Examples of the metal include, but are not limited to, nickel (Ni) powder, copper (Cu) powder, etc.

(26) In certain embodiment, the conductive heating composition may further include an additive, which may be a volume filler, a flame retardant, or a coupling agent. For example, the additive may be calcium carbonate, metal hydroxide, silane coupling agent, or combinations thereof. Examples of the metal hydroxide may include, but are not limited to, magnesium hydroxide, etc.

(27) FIGS. 4 and 5 illustrate a flexible conductive heating device according to a first embodiment of the disclosure. The flexible conductive heating device is flexible and has self-temperature-limiting and self-current-regulating properties. The flexible conductive heating device includes a flexible conductive heating substrate 100 and at least one first electrode unit 10. The flexible conductive heating substrate 100 is made of the conductive heating composition, and includes a first major surface 3 and a second major surface 4 opposite to the first major surface 3 in a thickness direction (Z) of the flexible conductive heating substrate 100.

(28) The first electrode unit 10 is formed on the first major surface 3, and includes a positive electrode 1 and a negative electrode 2. The positive electrode 1 includes a first base portion 11 and a plurality of first finger electrode portions 12 which extend respectively from the first base portion 11, and which are arranged to be separated from each other. The negative electrode 2 includes a second base portion 21, which is spaced apart from the first base portion 11, and a plurality of second finger electrode portions 22 which extend respectively from the second base portion 21, and which are arranged to be interdigitated with the first finger electrode portions 12. Two adjacent ones of the first and second finger electrode portions 12, 22 are spaced apart from each other by a first distance (d) ranging from 0.5 mm to 20 mm. Each of the first and second finger electrode portions 12, 22 is spaced apart from a respective one of the second and first base portions 21, 11 by a second distance (a). A ratio of the second distance (a) to the first distance (d) is larger than 0.8.

(29) In certain embodiments, the flexible conductive heating device may include a plurality of the first electrode units 10 which are electrically connected to each other in parallel.

(30) The flexible conductive heating device is prepared by the following steps a) to d).

(31) In step a), the components in the conductive heating composition are evenly mixed.

(32) In step b), the conductive heating composition is melt-blended and then granulated into composite pellets. The composite pellets may be formed by introducing the conductive heating composition into an extruder/granulator, such as a twin screw extruder (Leistritz ZSE 27 MAXX, screw L/D=42). The obtained composite pellets are then homogeneously mixed in a tank for 20 minutes.

(33) In step c), the flexible conductive heating substrate 100 is formed using the composite pellets through an extrusion process. The composite pellets may be extruded as the flexible conductive heating substrate 100 using a single-screw extruder (Labtech Engineering, LCR-350-HD, screw L/D=30). The extruder has an extrusion die of 0.1 mm, and is operated at a line speed of 0.8 m/min.

(34) In step d), the at least one first electrode unit 10 is formed on the first major surface 3 of the flexible conductive heating substrate 100. The step d) may be implemented by hot pressing a metal foil (not shown) on the first major surface 3 of the flexible conductive heating substrate 100 to form a metal layer on the first major surface 3, and patterning the metal layer to form the first electrode unit 10.

(35) In certain embodiments, a nickel coated copper foil is mounted on the flexible conductive heating substrate 100 by the hot pressing process followed by a cold pressing process to form a copper clad laminate. Thereafter, the copper layer on the laminate is patterned to form the first electrode unit 10.

(36) In certain embodiments, the first electrode unit 10 may be formed on the flexible conductive heating substrate 100 by screen printing a conductive paste or glue (such as not limited to a silver paste) on the first major surface 3.

(37) FIGS. 6 and 7 illustrate a flexible conductive heating device according to a second embodiment of the disclosure. The second embodiment is similar to the first embodiment except that in the second embodiment, the flexible conductive heating device further includes at least one second electrode unit 20 which is formed on the second major surface 4, and which includes a positive electrode 1 and a negative electrode 2. The positive electrode 1 includes a first base portion 11 and a plurality of first finger electrode portions 12. The negative electrode 2 includes a second base portion 21, which is spaced apart from the first base portion 11, and a plurality of second finger electrode portions 22 which are arranged in interdigitated relationship with the first finger electrode portions 12. Each of the first finger electrode portions 12 of the positive electrode 1 of the first electrode unit 10 is overlapped with a respective one of the second finger electrode portions 22 of the negative electrode 2 of the second electrode unit 20 in the thickness direction (Z) by at least 10 percent area. Each of the second finger electrode portions 22 of the negative electrode 2 of the first electrode unit 10 is overlapped with a respective one of the first finger electrode portions 12 of the positive electrode 1 of the second electrode unit 20 in the thickness direction (Z) by at least 10 percent area.

(38) In certain embodiments, the flexible conductive heating device may include a plurality of the first electrode units 10 which are electrically connected to each other in parallel, and a plurality of the second electrode units 20 which are electrically connected to each other in parallel.

(39) FIG. 8 illustrates a flexible conductive heating device according to a third embodiment of the disclosure. The third embodiment is similar to the second embodiment except that in the third embodiment, each of the positive and negative layers 1, 1, 2, 2 is coated with a layer 30 made of an insulating or thermal conductive material.

(40) FIGS. 9 and 10 illustrate a flexible conductive heating device according to a fourth embodiment of the disclosure. The fourth embodiment is similar to the second embodiment except that in the fourth embodiment, each of the first finger electrode portions 12 of the positive electrode 1 of the first electrode unit 10 is overlapped with a respective one of the first finger electrode portions 12 of the positive electrode 1 of the second electrode unit 20 in the thickness direction (Z) by at least 10 percent area. In addition, Each of the second finger electrode portions 22 of the negative electrode 2 of the first electrode unit 10 is overlapped with a respective one of the second finger electrode portions 22 of the negative electrode 2 of the second electrode unit 20 in the thickness direction (Z) by at least 10 percent area.

(41) The embodiments of the disclosure will now be explained in more detail below by way of the following examples and comparative examples. Those examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

First ExperimentBasic Properties

Example 1 (EX 1)

(42) 4500 g of a polyolefin elastomer (ethylene-octene copolymer purchased from LG chemical, Model: Lucene LC 170, melting point: 100 C., shore A: 91), 1000 g of high-density polyethylene (HDPE) (purchased from LyondellBasell, Model: Petrothene LB832001, melting point: 135 C.), 500 g of ethylene vinyl acetate copolymer (EVA) (purchased from Du Pont, Model: Elvax 760, melting point: 100 C.), 3000 g of carbon black (purchased form Spring Green Corp., Model: AS-32, mean particle size: 31 nm, DBP (dibutyl phthalate value): 72 cc/100 g), and 1000 g of calcium carbonate (purchased from Specialty minerals Inc., Model: Calcium meal 30, average particle size: 200 mesh, purity: greater than 98%) were poured into a container and evenly mixed at 25 C. for 20 minutes to obtain a premixed conductive composition powder of EX 1. The weight percents of the components in the conductive composition powder of EX 1 were listed in the following Table 1.

Example 2 (EX 2)

(43) A conductive composition of EX 2 was prepared according to the process employed for preparing the composition of EX 1, except that in EX 2, 4500 g of ethylene-propylene copolymer (purchased from Mitsui Chemicals, Model: TAFMER BL2491M, melting point: 100 C., shore A: 57) replaces the polyolefin elastomer of EX 1. The weight percents of the components in the premixed conductive composition powder of EX 2 were listed in Table 1.

Example 3 (EX 3)

(44) A conductive composition of EX 3 was prepared according to the process employed for preparing the composition of EX 1, except that in EX 3, the ethylene-octene copolymer (4500 g) was purchased from Dow Chemicals (Model: Engage 8200, melting point: 59 C., shore A: 66). The weight percents of the components in the premixed conductive composition powder of EX 3 were listed in Table 1.

Example 4 (EX 4)

(45) A conductive composition of EX 4 was prepared according to the process employed for preparing the composition of EX 2, except that in EX 4, the ethylene-1-butene copolymer (4500 g) was purchased from purchased from LG chemical (Model: Lucene LC 175, melting point: 42 C., shore A: 63). The weight percents of the components in the premixed conductive composition powder of EX 4 were listed in Table 1.

Comparative Example 1 (CE1)

(46) A conductive composition of CE 1 was prepared according to the process employed for preparing the composition of EX 1, expect that in CE 1, the polyolefin elastomer was not added. The conductive composition powder of CE 1 had ingredients similar to a conventional one. The weight percents of the components in the conductive composition powder of CE 1 were listed in Table 1.

Comparative Example 2 (CE2)

(47) A conductive composition of CE 2 was prepared according to the process employed for preparing the composition of EX 1, expect that in CE 2, the polyolefin elastomer was replaced with a thermoplastic elastomer purchased from Dow Chemical (Model: NORDEL EPDM 3722P, shore hardness: 71 A). The weight percents of the components in the conductive composition powder of CE 2 were listed in Table 1.

Preparation of Composite Pellets

(48) The conductive composition of each of EX 1 to EX 4, CE 1, and CE 2 was introduced into a twin screw extruder (Leistritz ZSE 27 MAXX, screw L/D=42). The twin screw extruder was operated at a screw speed of 120 rpm and a barrel temperature of about 240 C. with a 4 mm die and pelletizer to form composite pellets.

Preparation of Specimens

(49) The composite pellets made of the conductive composition of each of EX 1 to EX 4, CE 1, and CE 2 were homogeneously mixed in a tank for 20 minutes, and then molded and extruded as a substrate using a single-screw extruder (Labtech Engineering, LCR-350-HD, screw L/D=30). The extruder had an extrusion die of 0.1 mm, was operated at a line speed of 0.8 m/min, a screw speed of 30 rpm and 235 C. Finally, the substrate was cut into a plurality of first specimens (200 mm200 mm) and a plurality of second specimens (100 mm35 mm).

First TestSurface Resistivity

(50) For testing the composition of EX 1, two electrodes were formed in one of the first specimens made of the composition of EX 1. Each of the electrodes had an electrode length (EL) of 10 cm, and the electrodes were spaced apart by a spaced distance (SD) of 1.5 cm.

(51) A surface resistance of the first specimen made of the composition of EX 1 was measured using a resistance meter (HIOKI RM3544-01). The value of the surface resistance was shown on the resistance meter. A surface resistivity was calculated according to the following equation:
Surface resistance=Surface resistivityELSD

(52) Surface resistances and surface resistivities of the first specimens made of the compositions EX 2 to EX 4, CE 1, and CE 2 were also measured and calculated, respectively. The results were listed in Table 1.

Second TestVolume Resistivity

(53) Two metal foils (nickel coated copper foils purchased from Fukuda, Model: NIMT-CF, thickness: 0.035 mm) were respectively attached to two opposite surfaces of another first specimen made of the composition of EX 1, and then the first specimen with the two foil layers was disposed between two hot pressing plates, preheated for 3 minutes (10 psi, 200 C.), and hot-pressed for 5 minutes (100 psi) to obtain a laminate. The laminate was further subjected to a cool-pressing process (25 C., 100 psi) for 5 minutes. The laminate was cut into a test piece with an effective electrically conductive surface area (A) of 9 cm.sup.2 (30 mm30 mm). A thickness (T) of the test piece was measured using a Caliper (Mitutoyo 500-196-30). A resistance of the test piece was measured in a thickness direction using a resistance meter (HIOKI RM3544-01). The value of the resistance was shown on the resistance meter. A volume resistivity was calculated according to the following equation:
Volume resistivity=ResistanceAT

(54) Test pieces were also prepared from other first specimens of EX 2 to EX 4, CE 1, and CE 2, and resistances and volume resistivities for those test pieces were also measured and calculated, respectively. The results were listed in Table 1.

(55) TABLE-US-00001 TABLE 1 Item EX 1 EX 2 EX 3 EX 4 CE 1 CE2 Polyolefin 45 45 45 45 elastomer (wt %) Thermoplastic 45 elastomer (wt %) HDPE 10 10 10 10 40 10% (wt %) EVA 5 5 5 5 20 5 (wt %) Carbon black 30 30 30 30 30 30 (wt %) Calcium carbonate 10 10 10 10 10 10 (wt %) Surface Resistivity (surface area: 400 cm.sup.2) Surface resistance 225 1956 12135 28596 5 325895 (ohm) Surface resistivity 2E.+03 1E.+04 8E.+04 2E.+05 3E.+01 2E.+06 (ohm) Volume Resistivity (effective conductive area: 9.0 cm.sup.2) Thickness 0.025 0.027 0.018 0.018 0.015 0.032 (cm) Resistance 0.950 1.560 16.350 150.000 0.008 1500.000 (ohm) Volume resistivity 3.E+02 5.E+02 8.E+03 8.E+04 5.E+00 4.E+05 (ohm-cm)

Third TestTemperature Versus Resistance Curve Measurement

(56) Test pieces for the compositions of EX 1 to EX 4, CE 1, and CE 2 were prepared by a process similar to the process employed for preparing the test pieces of the second test. Resistances of the test pieces were measured at 20 C. using a resistance meter (KIOKI RM3544-01). Thereafter, the test pieces were placed in an oven for heating the test piece at a rate of 2 C./min. Resistances of the test piece were further measured each time when the temperature was raised by 10 C. until the temperature reached to 180 C. The results were shown in FIG. 11

(57) In the temperature interval between 20 C. and 90 C., a log value of the resistance of the test piece of each of EX 1 to EX 4, CE 1, and CE 2 increased with a slope which was calculated according to the following equation:

(58) $\text{Slope}=\frac{\log \left(R90\right)-\log \left(R20\right)}{90C.-20C.}$

(59) where R90 and R20 represent the resistances of the test pieces at 90 C. and 20 C., respectively.

(60) The calculated slopes were listed in Table 2.

(61) TABLE-US-00002 TABLE 2 Item EX 1 EX 2 EX 3 EX 4 EX 5 EX 6 Slope 3.77E02 3.77E02 5.39E02 8.68E02 1.29E02 6.97E03

Fourth TestBending Characteristics

(62) Before testing, surface resistances of second specimens made of the compositions of EX 1 to EX 4, CE 1, and CE 2 were measured using a surface resistance meter (HIOKI RM3544-01). Each of the second specimens was set in a De-mattia crack tester and repeatedly subjected to continuous tensile strain by a chuck distance of 57 mm and a stroke of 100 mm 300 times, according to the ISO 132/1999 procedure. After testing, surface resistances of specimens were further measured. The test results were listed in Table 3.

(63) TABLE-US-00003 TABLE 3 Item EX 1 EX 2 EX 3 EX 4 CE 1 CE 2 Before test 225 1956 12135 28596 5.3 325895 surface resistance (ohm) Appearance No damage No damage No damage No damage Damaged No damage After test 1128 3698 28653 63589 N/A 3658900 surface resistance (ohm) Increased rate* 401% 89% 136% 122% N/A 1023% ${}^{*}\mathrm{Increased}\mathrm{rate}=\frac{\mathrm{After}\mathrm{test}\mathrm{surface}\mathrm{resistance}-\mathrm{Before}\mathrm{test}\mathrm{surface}\mathrm{resistance}}{\mathrm{Before}\mathrm{test}\mathrm{surface}\mathrm{resistance}}100\%$*N/A: not available

(64) It can be found from Table 3 that although the composition CE 1, a well known PTC behavior polymer composition and without elastomer therein (see Table 1), was broken during bending test due to its high crystalline property. Furthermore, although the composition CE 2 which included thermoplastic elastomer was not damaged in the measurement according to ISO 132/1999 procedure, the resistance of the composition CE 2 did not sharply increase with the increasing temperature (see FIG. 11). In addition, after the measurement according to ISO 132/1999 procedure, the carbon black in the composition of CE 2 appeared to shift to cause the surface resistance greatly increase (increased rate: 1023%). Therefore, the compositions EX 1 to EX 4 including (i) a polyolefin elastomer, (ii) a crystalline non-grafted polyolefin (HDPE), (iii) a crystalline polymer which is grafted or copolymerized with a monomeric unit selected from carboxylic acid, carboxylic acid derivatives, and combinations thereof (EVA), and (iv) conductive filler (carbon black) may have better bending characteristics, and lower increased rate in the surface resistance after repeated subjected to the measurement according to ISO 132/1999 procedure 300 times.

Second ExperimentAging Test

Example 1A (EX 1A)

(65) A flexible conductive heating device of EX 1A was prepared according to the first embodiment shown in FIGS. 4 and 5, except that the flexible conductive heating device of EX 1A included ten of the first electrode units 10 which were parallel-connected. In EX 1A, the flexible conductive heating substrate 100 was made of the composition EX 1, and each of the first and second major surfaces 3, 4 had a surface area of 90.7 cm.sup.2 (75 mm121 mm). The first electrode units 10 were formed on the flexible conductive heating substrate 100 by screen-printing a silver paste on the first major surface 3. In addition, the positive electrode 1 of each of the first electrode units 10 included ten of the first finger electrode portions 12, and the negative electrode 2 of each of the first electrode units 10 included ten of the second finger electrode portions 22. The length (L) of each of the first and second finger electrode portions 12, 22, the first distance (d), and the second distance (a) shown in FIG. 4 were listed in Table 4 below.

Example 1A (EX 1A), Examples 2A to 4A (EX 2A to 4A) and Comparative Example 1A (CE 1A)

(66) Flexible conductive heating devices of EX 1A, EX 2A to 4A, and CE 1A were prepared to be similar to the flexible conductive heating device of EX 1A, except for the material for forming the flexible conductive heating substrate 100, and the parameters for the first electrode unit(s), i.e., the length (L) of each of the first and second finger electrode portions 12, 22, the first distance (d), the second distance (a), the ratio (a/d), and the number of the first electrode unit(s) 10, which were listed in Table 4.

(67) Each of the flexible conductive heating devices of EX 1A, EX 1A, EX 2A to 4A and CE 1A was subjected to an aging test by applying a test voltage (listed in Table 4) to the respective flexible conductive heating device for 1000 hours, and the resistance for each flexible conductive heating device was measured before and after the aging test. The results were also listed in Table 4.

(68) TABLE-US-00004 TABLE 4 Item EX 1A EX 1A' EX 2A EX 3A EX 4A CE 1A Material EX 1 EX 1 EX 2 EX 3 EX 4 CE 1 Size of each of the first and second major surfaces Length (mm) 75 260 160 880 520 206 Width (mm) 121 125 125 140 190 190 Surface area 90.75 325 200 1232 988 391.4 Parameters for the first electrode unit(s) d (mm) 0.5 10.0 5.0 20.0 10.0 100.0 L (mm) 100 100 100 100 150 150 a (mm) 0.45 5.00 5.00 20.00 20.00 20.00 a/d 0.90 0.50 1.00 1.00 2.00 0.20 Electrode unit 10 10 10 20 20 1 number* Parameters and results for aging test Test voltage 5 12 48 250 250 48 (volt) Test period 1000 1000 1000 1000 1000 1000 (hour) Surface 2.E+03 2.E+03 1.E+04 8.E+04 9.E+05 3.E+01 resistivity (ohm) Before test 1.13 18.00 71.72 687.65 590.98 33.33 resistance (ohm) After test 1.72 191.70 168.54 1155.25 1170.15 28533.33 resistance (ohm) Increased rate* 53% 965% 135% 68% 98% 85500% *Electrode unit number: number of the first electrode unit(s) ${}^{*}\mathrm{Increased}\mathrm{rate}=\frac{\mathrm{After}\mathrm{test}\mathrm{resistance}-\mathrm{Before}\mathrm{test}\mathrm{resistance}}{\mathrm{Before}\mathrm{test}\mathrm{surface}\mathrm{resistance}}100\%$

(69) During the aging test, hot-lines were found in the flexible conductive heating device of CE 1A. Although the device CE 1A was still operable in the test, the increased rate in the resistance, after the voltage was applied for 1000 hours, reached to 85500%. This is because of the uneven heat distribution in the flexible conductive heating device CE 1A. In this case, polymer structures in higher temperature zones of the flexible conductive heating substrate may be seriously destroyed, making the resistance in those zones undue large, thereby forming the hot lines which are likely formed between the positive and negative electrodes to be connected in series.

(70) Furthermore, it can be found that when the ratio (a/d) was ranged from 0.8 to 2 (especially, from 0.9 to 1.0), the increased rate in the resistance, after the voltage was applied for 1000 hours, was relatively small. This is because when the first finger electrode portions 12 are closer to the second base portion 21, the point discharge phenomenon becomes manifest. This means the current can be evenly flow between the positive and negative electrodes. Therefore, it can be concluded that when the ratio (a/d) is greater than 0.8, especially when the ratio (a/d) ranges from 0.8 to 2.0, more even heat distribution in the flexible conductive heating device may be achieved, thereby alleviating the problems caused by the formation of hot-lines in the flexible conductive heating device.

Third Experiment

Example 5 to Example 8 (EX 5 to 8)

(71) Each of conductive heating compositions of EX 5 to 8 was prepared according to the process employed for preparing the composition of EX 2 in the first experiment, except for the weight percents of the components which were listed in the following Table 5.

(72) First and second specimens for each of the compositions of EX 5 to 8 were prepared in the same manner described in the first experiment. The compositions of EX 5 to 8 were subjected to tests for Surface Resistivity, Volume Resistivity, Temperature versus Resistance Curve Measurement, and Bending Characteristics, as described in the first experiment. The results were shown in Table 5 and in FIG. 12.

(73) TABLE-US-00005 TABLE 5 Item EX 5 EX 6 EX 7 EX 8 Polyolefin 49 39 15 10 elastomer* (wt %) HDPE (wt %) 10 10 22 25 EVA (wt %) 5 5 23 25 Carbon black (wt %) 26 36 30 30 Calcium carbonate (wt %) 10 10 10 10 Surface Resistivity (surface area: 400 cm.sup.2) Surface resistance (ohm) 158600 8.6 1284 589 Surface resistivity (ohm) 1.E+06 6.E+01 9.E+03 4.E+03 Volume Resistivity (effective conductive area: 9.0 cm.sup.2) Thickness (cm) 0.021 0.032 0.015 0.015 Resistance (ohm) 153.000 0.300 0.930 0.870 Volume resistivity (ohm-cm) 7.E+04 8.E+01 6.E+02 5.E+02 Temperature versus Resistance Curve Measurement Slope (ohm/ C.) 5.19E+02 6.62E+02 5.69E+02 5.17E+02 Bending characteristics Before test surface resistance 158600.0 8.6 1284.0 589.0 (ohm) Appearance No damaged No damaged No damaged No damaged After test surface resistance 356820.0 30.7 2858.0 2325.0 (ohm) Increased rate* 125% 257% 123% 295% *Polyolefin elastomer: ethylene-propylene copolymer (purchased from Mitsui Chemicals, Model: TAFMER BL2491M, melting point: 100 C., shore A:57) ${}^{*}\mathrm{Increased}\mathrm{rate}=\frac{\mathrm{After}\mathrm{test}\mathrm{surface}\mathrm{resistance}-\mathrm{Before}\mathrm{test}\mathrm{surface}\mathrm{resistance}}{\mathrm{Before}\mathrm{test}\mathrm{surface}\mathrm{resistance}}100\%$

(74) Because the polyolefin elastomer (which is provided with crystalline property) and the crystalline non-grafted polyolefin in the compositions of EX 5 to EX 8 have good compatibility therebetween, the compositions of EX 5 to EX 8, as shown in Table 5 and FIG. 12, had good mechanical and electrical properties, and self-limiting and regulating properties.

Examples 5A to 8A (EX 5A to 8A)

(75) Flexible conductive heating devices of EX 5A to 8A were prepared to be similar to the flexible conductive heating device of EX 1A, except for the material for forming the flexible conductive heating substrate 100, and the parameters for the first electrode unit(s), i.e., the length (L) of each of the first and second finger electrode portions 12, 22, the first distance (d), the second distance (a), the ratio (a/d), and the number of the first electrode unit(s) 10, which were listed in Table 6.

(76) Each of the flexible conductive heating devices of EX 5A to 8A was subjected to the aging test described in the second experiment, and the results were also shown in Table 6.

(77) In addition, each of the flexible conductive heating devices of EX 5A to 8A was further subjected to a self temperature limiting test according to UL standard 1434 11.6 by applying a voltage of 12 Vdc at 25 C. Maximum surface temperature and maximum residual current of each test were also recorded in Table 6. A test result of EX 6A was also shown in FIG. 13.

(78) Furthermore, EX 6A was further tested according to UL standard 1434 11.6 by applying a voltage of 12 Vdc under an ambient temperature (AT=30 C.) and a lower ambient temperature (AT=20 C.). The results was shown in FIG. 14.

(79) TABLE-US-00006 TABLE 6 Item EX 5A EX 6A EX 7A EX 8A Material EX 5 EX 6 EX 7 EX 8 Parameters for the first electrode units d (mm) 2.5 18.0 0.5 0.5 L (mm) 80 50 80 80 a (mm) 5.00 15.00 0.50 3.00 a/d 2.00 0.83 1.00 6.00 Electrode unit 45 8 20 6 number* Parameters and results for aging test Test voltage (volt) 250 12 12 12 Test period (hour) 1000 1000 1000 1000 Max. surface 46.3 75.4 56.7 64.3 temperature ( C.) Max. residual 0.02 0.19 0.09 0.11 current (A) Surface resistivity 1.E+06 6.E+01 9.E+03 4.E+03 (ohm) Before test 1041.67 3.24 3.09 3.54 resistance (ohm) After test 3072.92 8.59 22.74 23.66 resistance (ohm) Increased rate* 195% 165% 635% 568% *Electrode unit number: the number of the first electrode units ${}^{*}\mathrm{Increased}\mathrm{rate}=\frac{\mathrm{After}\mathrm{test}\mathrm{resistance}-\mathrm{Before}\mathrm{test}\mathrm{resistance}}{\mathrm{Before}\mathrm{test}\mathrm{surface}\mathrm{resistance}}100\%$

(80) It can be found from Table 6 that when the same voltage (12 Vdc) was applied to the flexible conductive heating devices of EX 6A to EX 8A, the flexible conductive heating devices of EX 6A and 8A had relatively large increased rate in the resistance (i.e., relatively large aging rate). This is because that the compositions EX 7 and EX 8 used in EX 7A and EX 8A had relatively low concentrations of carbon black and polyolefin elastomer, and relatively high concentrations of HDPE which may be destroyed during the aging test. Therefore, the polyolefin elastomer may be in an amount ranging from 10 wt % to 50 wt %, preferably greater than 15 wt % to 50 wt %, and more preferably 39 wt % to 50 wt % based on 100 wt % of a total weight of the conductive composition.

(81) It can be found in FIG. 13 that after the voltage (12 Vdc) was applied for 500 minutes, the surface temperature was kept at a small range (about 55-60 C.), and the current was also kept at about 0.22 A. Therefore, the flexible conductive heating device of EX 6A had self temperature limiting property.

(82) It can be found in FIG. 14 that the flexible conductive heating device of EX 6A may self regulate the current passing therethrough under different ambient temperatures so as to compensate for the ambient temperature.

Fourth Experiment

Example 1B (EX 1B)

(83) A flexible conductive heating device of EX 1B was prepared according to the second embodiment shown in FIGS. 6 and 7, except that the flexible conductive heating device of EX 1B included ten of the first electrode units 10 which were parallel-connected and ten of the second electrode units 20 which were parallel-connected. In EX 1B, the flexible conductive heating substrate 100 was made of EX 1. The first and second electrode units 10, 20 were formed on the flexible conductive heating substrate 100 by screen-printing a silver paste on the first and second major surfaces 3, 4, respectively. In addition, each of the positive electrodes 1, 1 of the first and second electrode units 10, 20 included ten of the first finger electrode portions 12, 12, and each of the negative electrodes 2, 2 of the first and second electrode units 10, 20 included ten of the second finger electrode portions 22, 22. The length (L) of each of the first and second finger electrode portions 12, 12, 22, 22, the first distance (d), and the second distance (a) shown in FIG. 6 were listed in the following Table 7. In addition, the number of the first electrode units 10 which is equal to the number of the second electrode units 20, an overlapping area of the first and second electrode units 10, 20 in the thickness direction (Z) shown in FIG. 7, and a total surface area of the first electrode units 10, which is equal to a total surface area of the second electrode units 20, were also listed in Table 7.

Example 2B (EX 2B)

(84) Flexible conductive heating device of EX 2B was prepared as similar as EX 1B, except for the material for forming the flexible conductive heating substrate 100, and the parameters for the first electrode unit(s), i.e., the first distance (d), the second distance (a), the ratio (a/d), and the overlapping area, which were listed in Table 7.

(85) TABLE-US-00007 TABLE 7 Item EX 1B EX 2B Material EX 1 EX 2 Parameters for the first/second electrode units Thickness* (mm) 0.25 0.27 d (mm) 0.5 5.0 L (mm) 100 100 a(mm) 0.45 5.00 a/d 0.90 1.00 Electrode unit number* 10 10 Total surface area of the electrode units* (cm.sup.2) 20 20 Overlapping area* 10 9.3 Overlapping ratio* 50 46.50 Volume resistivity (ohm-cm) 342 520 Parameters and results for aging test Test voltage (volt) 5 48 Test period (hour) 1000 1000 Before test resistance (ohm) 0.94 2.25 After test resistance (ohm) 3.02 7.53 Increased rate* 221% 235% *Thickness: a thickness of the flexible conductive heating device *Electrode unit number: the number of the first electrode units, which is equal to the number of the second electrode units *Total surface area of the electrode units: a total surface area of the first electrode units, which is equal to a total surface area of the second electrode units *Overlapping area: an overlapping area of the first and second electrode units 10, 20 in the thickness direction (Z) shown in Fig. 7 ${}^{*}\mathrm{Overlapping}\mathrm{ratio}=\frac{\mathrm{Overlapping}\mathrm{area}}{\mathrm{Total}\mathrm{surface}\mathrm{area}\mathrm{of}\mathrm{the}\mathrm{electrode}\mathrm{units}}100\%$${}^{*}\mathrm{Increased}\mathrm{rate}=\frac{\mathrm{After}\mathrm{test}\mathrm{resistance}-\mathrm{Before}\mathrm{test}\mathrm{resistance}}{\mathrm{Before}\mathrm{test}\mathrm{resistance}}100\%$

(86) With the provision of the first and second electrode units 10, 20 on the first and second major surfaces 3, 4 of the flexible conductive heating substrate 100, the temperature differences between the first and second major surfaces 3, 4 may be reduced. The current may be forced to flow in the thickness direction (Z) and an in-plane direction. Therefore, the flexible conductive heating devices of EX 1B and EX 2B may have more even heat distribution.

(87) When the flexible conductive heating device of the disclosure is heated from 20 C. to 90 C., a log value of a resistance of the conductive heating composition increases with a slope ranging from 3E02 log ohm/ C. to 9E02 log ohm/ C. This means that in temperature ranging from 20 C. to 90 C., the resistance of the flexible conductive heating device may be varied by variation of the applied voltage so as to permit the flexible conductive heating device to have a desired temperature. For example, the flexible conductive heating device of EX 2B was measured to have an initial resistance of 3 ohm. After 12 Vdc was applied to the device EX 2B for 5 minutes, a current measured from the device EX 2B was 0.10 A and a temperature measured from the device EX 2B was 58 C. This means that the resistance of the device EX 2B was raised to 120 ohm (12/0.10=120). The composition EX 2 was used in the device of EX 2B. In the temperature versus resistance graph shown in FIG. 11, when the resistance is raised to 120 ohm, the temperature of the composition EX 2 is theoretically raised to 60 C., which is close to the real temperature (58 C.). Furthermore, after 24 Vdc was applied to the device EX 2B for 5 minutes, a current measured from the device EX 2B was 0.05 A and a temperature measured from the device EX 2B was 81 C. This means that the resistance of the device EX 2B was raised to 480 ohm (24/0.05=480). In the temperature versus resistance graph shown in FIG. 11, when the resistance is raised to 480 ohm, the temperature of the composition EX 2 is theoretically raised to 80 C., which is close to the real temperature (81 C.).

(88) In sum, the flexible conductive heating device of the disclosure is sensitive to current and temperature and has good mechanical and electrical properties and self limiting and self regulating properties. Therefore, the flexible conductive heating device of the disclosure is less likely to have safety concerns, and is useful in the fields of heating devices, heat preservation devices, over-current protection devices, etc.

(89) In the description above, for the purposes of explanation, numerous specific details have been set forth in order to provide a thorough understanding of the embodiment(s). It will be apparent, however, to one skilled in the art, that one or more other embodiments may be practiced without some of these specific details. It should also be appreciated that reference throughout this specification to one embodiment, an embodiment, an embodiment with an indication of an ordinal number and so forth means that a particular feature, structure, or characteristic may be included in the practice of the disclosure. It should be further appreciated that in the description, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of various inventive aspects, and that one or more features or specific details from one embodiment may be practiced together with one or more features or specific details from another embodiment, where appropriate, in the practice of the disclosure.

(90) While the disclosure has been described in connection with what is (are) considered the exemplary embodiment(s), it is understood that this disclosure is not limited to the disclosed embodiment(s) but is intended to cover various arrangements included within the spirit and scope of the broadest interpretation so as to encompass all such modifications and equivalent arrangements.