Method for manufacturing of film heater

Abstract

The present invention relates to a method for manufacturing a film heater with excellent heat resistance and improved insulation properties by forming a heater pattern constituting a heating wire between an upper mica and a lower mica. The method comprises the steps of: preparing a lower mica having one side containing an adhesive component; depositing and laminating a metal foil on the side of the lower mica having the adhesive component to attach it; forming a lead terminal to which power is selectively applied and a heater pattern on the metal foil attached to the lower mica; mounting a film-type temperature sensor for controlling the current of the heater pattern in a mounting groove formed on the back surface of the metal foil to integrate it; laminating an upper mica on the upper part of the metal foil on which the film-type temperature sensor is mounted; performing a laminating operation on the metal foil on which the upper mica is laminated so that the metal foil is combined in a sandwich structure between the upper mica and the lower mica; and attaching an insulating layer having an air gap to minimize external heat generation and heat loss.

Description

Technology Field

[0001] The present invention relates to a hair straightener, and more particularly to a method for manufacturing a film heater that has excellent heat resistance and improved insulation properties. Background Technology

[0002] Generally, hair straighteners use heat to straighten or bend hair while it is wrapped or clamped, creating desired hairstyles. In the past, straighteners with intersecting heaters that heated the hair were the mainstream, but recently, electric straighteners with clamp-like heating functions have become the mainstream for greater convenience.

[0003] The heaters of these electric hair straighteners are heated by electricity supplied from an external source and are generally made of metal materials with excellent thermal conductivity to enable rapid heating. Among metals, aluminum or aluminum alloys, which have particularly excellent thermal conductivity, are most widely used.

[0004] However, when using a metal material with such high thermal conductivity as a heater, the heating plate heats up instantly due to the high thermal conductivity, which burns the hair or destroys the keratin, a protein component that forms the hair, causing severe damage to the hair.

[0005] In addition, since the heater is made of metal, although it has excellent heat generation, it cools down easily, and due to the characteristics of metal with insufficient thermal emissivity, the radiated high heat acts only on the surface of the hair and is not transmitted deep into the interior of the hair, so there was a problem in that the hair styling time was long and the styled hair was severely damaged and could not be restored to its original state. The problem to be solved

[0006] The present invention has been devised to achieve the above objectives, and aims to provide a method for manufacturing a film heater with excellent heat resistance and improved insulation by forming a heater pattern constituting a heating wire between an upper mica and a lower mica. means of solving the problem

[0007] A film heater according to the present invention for achieving the above-mentioned purpose is characterized by comprising a metal foil having a lead terminal to which power is applied on one surface and a plurality of heater patterns, an upper mica attached to the front surface of the metal foil including the lead terminal, and a lower mica attached to the back surface of the metal foil.

[0008] In addition, the method for manufacturing a film heater according to the present invention to achieve the above-mentioned purpose comprises the steps of: preparing a lower mica; attaching a metal foil to the lower mica and performing a laminating operation; selectively etching the metal foil to form lead terminals for applying power including a heater pattern; and attaching an upper mica to the front surface including the heater pattern and performing a laminating operation.

[0009] In addition, the method for manufacturing a film heater according to the present invention to achieve the above-mentioned purpose comprises the steps of: preparing a metal thin plate; attaching a lower mica to one side of the metal thin plate and performing a laminating operation; selectively etching the metal thin plate to form lead terminals for applying power including a heater pattern; and attaching an upper mica to the front surface including the heater pattern and performing a laminating operation. Effects of the invention

[0010] The method for manufacturing a film heater according to an embodiment of the present invention has the following effects.

[0011] In other words, by manufacturing a heater by forming a heater pattern that constitutes a heating element between the upper mica and the lower mica, insulation can be improved and heat resistance can be increased. Brief explanation of the drawing

[0012] FIG. 1 is a perspective view showing a film heater according to the present invention. FIG. 2 is a cross-sectional view showing a film heater along the line II-II' of FIG. 1. FIGS. 3 to 7 are process perspective views illustrating a method for manufacturing a film heater according to the present invention. Specific details for implementing the invention

[0013] Hereinafter, embodiments of the present invention are described in detail with reference to the attached drawings so that those skilled in the art can easily implement the invention. However, the present invention may be embodied in various different forms and is not limited to the embodiments described herein. Furthermore, in order to clearly explain the present invention in the drawings, parts unrelated to the explanation have been omitted, and similar parts throughout the specification are denoted by similar reference numerals.

[0014] Throughout the specification, when a part is described as "including" a certain component, this means that, unless specifically stated otherwise, it does not exclude other components but may include additional components.

[0015] FIG. 1 is a perspective view showing a film heater according to the present invention, and FIG. 2 is a cross-sectional view showing a film heater along the line II-II' of FIG. 1.

[0016] As shown in FIGS. 1 and 2, the film heater (100) according to the present invention comprises a metal foil (110) having a lead terminal (111) to which power is applied on one side and a plurality of heater patterns (112), an upper mica (120) formed on the front surface of the metal foil (110) excluding the lead terminal (111), and a lower mica (130) formed on the back surface of the metal foil (110).

[0017] Here, the lead terminal (111) is the part where a power cable is connected to supply power to one end of the film heater (100).

[0018] The above metal sheet (110) is made of a material including one of aluminum (Al), copper (Cu), silver (Ag), gold (Au), chrome (Cr), nickel (Ni), platinum (Pt), stainless steel, titanium (Ti), or Alcott, and alloys thereof, which have excellent thermal conductivity.

[0019] In addition, the metal sheet (110) is made of a metal material with excellent volume fraction or a metal material with excellent thermal equilibrium, using carbon fiber, artificial graphite, activated carbon, carbon black, carbon nanotubes (CNT), or graphene carbon raw materials.

[0020] Meanwhile, the heater pattern (113) is patterned to form a heating element in the film heater, for example, by processing copper, nickel, stainless steel, etc. into a thin sheet in micron units, and heat is generated when power is applied from the outside.

[0021] The above metal thin plate (110) is formed with a thickness of 40 to 50 microns and a power consumption of 3 kW or less.

[0022] Here, the upper mica (120) and lower mica (130) are materials that have excellent heat resistance and can withstand high temperatures of about 500 to 1000°C without deforming or burning, and also have excellent insulation properties that completely block the electric heater pattern and the outer metal case to prevent leakage or electric shock.

[0023] In addition, the upper mica (120) and lower mica (130), despite being insulators, have a good ability to transfer heat, so they can transfer heat generated from the heater pattern to the heating target relatively efficiently, and can be made into a thin plate shape so they take up little space and are easy to bend or cut, so they can be applied to heaters of various shapes.

[0024] Therefore, by using the upper mica (120) and lower mica (130) above to mold the entire surface of the film heater (100) according to the present invention, insulation and heat resistance can be improved.

[0025] That is, by forming the metal sheet (110) into a sandwich structure using the upper mica (120) and lower mica (130), it has durability capable of withstanding high temperatures of 600°C or higher, and after forming the upper mica (120) and lower mica (130), it can be used as a hair styling surface through ceramic coating, thus having an excellent film heater structure.

[0026] In addition, by using the upper mica (120) and lower mica (130) as insulators, the heat conduction speed is faster than other insulators, so the preheating time can be drastically shortened, and when heated, far-infrared rays are emitted from the upper mica (120) and lower mica (130), so hair damage can be drastically reduced.

[0027] Meanwhile, in the embodiment of the present invention, a single-layer film heater is described in which an upper mica (120) and a lower mica (130) are formed with the heater pattern (112) in between, but the invention is not limited thereto and a multi-layer film heater may be formed, that is, the heater pattern (112) may be formed on the upper mica (120) and the upper mica may be formed thereon.

[0028] FIGS. 3 to 7 are process perspective views showing a method for manufacturing a film heater according to the present invention.

[0029] A method for manufacturing a film heater according to the present invention prepares a lower mica (130) as shown in FIG. 3 (S110). Here, the lower mica (130) has an adhesive component on one side.

[0030] As shown in FIG. 4, a metal foil (110) is deposited on the surface of the lower mica (130) that has an adhesive component, and a lamination operation is performed to attach the metal foil (110) to the upper surface of the lower mica (130).

[0031] Here, with the metal sheet (110) prepared, a lower mica (130) may be attached to one side of the metal sheet (110) and a laminating process may be performed.

[0032] Generally, since mica and metal sheets are different materials, their coefficients of thermal expansion differ, making them prone to delamination or peeling when used repeatedly. However, in the present invention, chemical / process integration rather than physical bonding is achieved through adhesive components, lamination, and deposition processes, thereby preventing the metal sheet (110) from peeling off from the lower mica (130) even under rapid temperature changes.

[0033] In addition, the metal thin plate (110) can be formed through at least one selected from sputtering, ion plating, arc deposition, ion beam assisted deposition, and resistance heating vacuum evaporation.

[0034] The above metal thin plate (110) is formed with a thickness of 40 to 50 microns so that it can be heated within 3 kW of power consumption. That is, the above metal thin plate (110) prevents overheating, ensuring safe use, and significantly reduces the flow of current, thereby minimizing power consumption.

[0035] In addition, it is preferable that the metal sheet (110) has a positive temperature coefficient (PTC). In this case, it has a relatively small resistance value at low temperatures, and when it rises to a predetermined temperature, the resistance value increases significantly, and the temperature rise decreases significantly.

[0036] The above metal sheet (110) is made of a material including one of aluminum (Al), copper (Cu), silver (Ag), gold (Au), chrome (Cr), nickel (Ni), platinum (Pt), stainless steel, titanium (Ti), or Alcott, and alloys thereof, which have excellent thermal conductivity.

[0037] In addition, the metal sheet (110) is made of a metal material with excellent volume fraction or a metal material with excellent thermal equilibrium, such as carbon fiber, artificial graphite, activated carbon, carbon black, carbon nanotubes (CNT), or graphene carbon raw material.

[0038] Meanwhile, prior to proceeding with the laminating process, surface energy is controlled through a pretreatment process to remove foreign substances from the surface of the metal sheet (110) and the lower mica (130) and to increase adhesion. Specifically, a degreasing process is performed to remove oil and dust from the surface of the metal sheet (110) using chemicals, and an acid pickling process is performed to remove the oxide film on the metal surface. Then, the surface of the lower mica (130) is struck with plasma to increase surface energy.

[0039] Next, once the pretreatment process is completed, a laminating process is carried out by applying heat and pressure. At this time, the laminating process is performed using either a roll-to-roll method or a vacuum hot press method. The roll-to-roll method proceeds sequentially with preheating, hot roller compression, and cooling, while the vacuum hot press method proceeds with lamination, vacuum suction, heating, and pressurization.

[0040] As shown in FIG. 5, the metal foil (110) is selectively etched to form lead terminals (111) and heater patterns (112), respectively. At this time, the etching is performed by a photolithography process using wet or dry etching.

[0041] Here, if a metal film is deposited on the upper part of the lower mica (130) and etching is performed, the width of the heater pattern (112) can be controlled in micrometers (μm).

[0042] Meanwhile, the lead terminal (111) including the heater pattern (112) on the metal foil (110) may also be formed by screen printing.

[0043] The heater pattern (112) formed by selectively etching the metal thin plate (110) is patterned and formed as a heating element of the film heater in the present invention, for example, copper, nickel, stainless steel, etc., are processed into a thin plate in micron units and generate heat when power is applied from the outside.

[0044] As shown in FIG. 6, an upper mica (120) is laminated on the front surface where the heater pattern (112) is formed.

[0045] Meanwhile, before laminating the upper mica (120), a temperature sensor (not shown) for measuring the temperature of a film heater may be additionally formed on the metal foil (110) on which the heater pattern (112) is formed. The temperature sensor may be formed so as to be seated in the mounting groove formed on the back surface of the metal foil (110).

[0046] Specifically, the temperature sensor measures the temperature of the film heater and controls the current flowing through the heater pattern (112) through the temperature value to achieve the desired temperature. By placing the temperature sensor at the exact center of the heater pattern (112), the most accurate temperature value can be measured.

[0047] As shown in Fig. 7, the upper mica (120) is laminated onto the metal foil (110) to complete the heater manufacturing process.

[0048] In addition, a ceramic coating may be applied after attaching to the front surface of the metal sheet (110) including the upper mica (120). Here, through the ceramic coating, the surface can be used as a surface that comes into direct contact with the hair when styling hair with a hair iron or hair dryer, thereby providing an excellent heating plate structure.

[0049] The ceramic coating described above makes the surface smooth, preventing hair from burning or being damaged during styling. Since the coating layer is not formed only on the surface but is molded integrally with the surface through heat fusion, the coating effect can be maintained even if the surface peels off during use.

[0050] Meanwhile, in the embodiment of the present invention, a single-layer film heater is described in which an upper mica (120) and a lower mica (130) are formed with the heater pattern (112) in between, but the invention is not limited thereto and a multi-layer film heater may be formed, that is, the heater pattern (112) may be formed on the upper mica (120) and the upper mica may be formed thereon.

[0051] Generally, as film heaters must reach 300°C within 20 seconds, heat transfer and thermal efficiency are very important. Therefore, to detect this rate of temperature increase, it is essential to integrate a film-type temperature sensor with a very fast response speed with the film-type heater.

[0052] In the present invention, a film heater and a temperature sensor are integrated with a thickness of 200 μm or less, and an insulating layer is attached to have an air gap to minimize external heat generation, thereby forming a film heater that minimizes heat loss and can precisely detect heat transfer and heating rates.

[0053] At this time, if the upper mica (120) is formed into a sandwich structure on the front surface including the metal sheet (110), perfect waterproofing and overall durability of the film heater are improved, and through surface heating, a temperature rise rate more than twice as fast can be achieved even with 50% power consumption.

[0054] Here, the upper mica (120) and lower mica (130) are materials that have excellent heat resistance and can withstand high temperatures of about 500 to 1000°C without deforming or burning, and also have excellent insulation properties that completely block the electric heater pattern and the outer metal case to prevent leakage or electric shock.

[0055] In addition, the upper mica (120) and lower mica (130), despite being insulators, have a good ability to transfer heat, so they can transfer heat generated from the heater pattern to the heating target relatively efficiently, and can be made into a thin plate shape so they take up little space and are easy to bend or cut, so they can be applied to heaters of various shapes.

[0056] Therefore, by using the upper mica (120) and lower mica (130) above to mold the entire surface of the film heater (100) according to the present invention, insulation and heat resistance can be improved.

[0057] That is, by forming the metal sheet (110) into a sandwich structure using the upper mica (120) and lower mica (130), it has durability capable of withstanding high temperatures of 600°C or higher, and after forming the upper mica (120) and lower mica (130), it can be used as a hair styling surface through ceramic coating, thus having an excellent film heater structure.

[0058] In addition, by using the upper mica (120) and lower mica (130) as insulators, the heat conduction speed is faster than other insulators, so the preheating time can be drastically shortened, and when heated, far-infrared rays are emitted from the upper mica (120) and lower mica (130), so hair damage can be drastically reduced.

[0059] Meanwhile, although the technical concept of the present invention has been described above together with the accompanying drawings, this is merely an illustrative explanation of preferred embodiments of the present invention and is not intended to limit the invention. Furthermore, it is evident that anyone with ordinary knowledge in the technical field to which the present invention pertains can make various modifications and imitations within the scope of the technical concept of the present invention without departing from its scope. Explanation of the symbols

[0060] 110: Metal foil 111: Lead terminal 112: Heater pattern 120: Upper mica 130 : Lower mica

Claims

Claim 1 delete Claim 2 A method for manufacturing a film heater, characterized by comprising: a step of preparing a lower mica having one side containing an adhesive component; a step of depositing and laminating a metal foil onto the side of the lower mica having the adhesive component to attach it; a step of forming a lead terminal to which power is selectively applied and a heater pattern on the metal foil attached to the lower mica; a step of mounting a film-type temperature sensor for controlling the current of the heater pattern in a mounting groove formed on the back surface of the metal foil to integrate it; a step of laminating an upper mica on the upper part of the metal foil on which the film-type temperature sensor is mounted; a step of performing a laminating operation on the metal foil on which the upper mica is laminated so that the metal foil is combined in a sandwich structure between the upper mica and the lower mica; and a step of attaching an insulating layer having an air gap to minimize external heat generation and heat loss. Claim 3 delete Claim 4 A method for manufacturing a film heater according to claim 2, characterized by attaching another metal foil to the upper mica and performing a laminating operation, then forming a heater pattern, and attaching another upper mica thereon and manufacturing a multilayer film heater through a laminating operation. Claim 5 delete

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