WO2009025429A1

WO2009025429A1 - Impregnated heating sheet, heating board and the method thereof

Info

Publication number: WO2009025429A1
Application number: PCT/KR2008/000628
Authority: WO
Inventors: Jang-Hyun Nam
Original assignee: DONGWHA NATURE FLOORING Co Ltd
Current assignee: DONGWHA NATURE FLOORING Co Ltd
Priority date: 2007-08-21
Filing date: 2008-02-01
Publication date: 2009-02-26
Anticipated expiration: 2010-02-21

Abstract

Disclosed are an impregnated heating sheet obtained by impregnating carbon paper and copper foil strips with a thermosetting resin including melamine, a heating board using the same and a manufacturing method thereof, and a heating board using impregnated thermosetting resin paper and a manufacturing method thereof. The impregnated heating sheet includes carbon paper for generating heat using electrical resistance and copper foil strips provided to the carbon paper to apply electricity to the carbon paper, wherein the carbon paper and the copper foil strips are subjected to low pressure melamine impregnation using the thermosetting resin including melamine. The heating board is manufactured by laminating the impregnated heating sheet, in which the thermosetting resin including melamine is incorporated, on the bottom surface of a woody board, or is integratedly formed using the impregnated thermosetting resin paper, thus simplifying the manufacturing process, facilitating maintenance, repair and replacement of products, and enabling the manufacture of heating boards so that the shape of boards for con¬ ventional interior and furniture materials can be maintained unchanged, thereby being useful as interior heating boards having various forms.

Description

IMPREGNATED HEATING SHEET, HEATING BOARD AND

THE METHOD THEREOF

Technical Field

[1] The present invention relates to an impregnated heating sheet, in which carbon paper for generating heat using electrical resistance and copper foil strips for applying electricity to the carbon paper are impregnated with a thermosetting resin including melamine, to a heating board in which the impregnated heating sheet is laminated on the bottom surface of a woody board through hot pressing and a manufacturing method thereof, and to a heating board, which is integrally formed using impregnated thermosetting resin paper and a manufacturing method thereof. Background Art

[2] Generally, a warming system for use in various building facilities is constructed such that heat is generated from an under-floor heating pipe arrangement or electric heater through the application of power and is then transferred to a heat conductive layer and a floor material, after which indoor air is circulated, thus realizing warming.

[3] In a conventional warming system, a heater in a hot wire form is directly used, or alternatively, a planar heater is mainly embodied as a film in a linear heater form.

[4] Among them, in the case where the heater in a hot wire form is used, heat is intensively generated only around the place where the heater is mounted, undesirably causing problems related to a decrease in warming efficiency and unnecessary energy consumption.

[5] Further, unexpected accidents, such as fires, may be caused by sparks due to overheating at the place where heat is intensively generated. Moreover, the extended use of such a warming system incurs problems related to the propagation of various microbes, including mold, which are harmful to the human body, attributable to accumulated moisture.

[6] In addition, in the case where the film type heater, such as a planar heater or a linear heater, is used, it may break under even a small impact, thus making it impossible to use it for a long period of time, and thus it should be periodically replaced, which is cumbersome.

[7] With the goal of solving such problems, Korean Unexamined Patent Publication

No. 2007-54152 discloses a heating board for warming, having a configuration in which heating wires are arranged internally and magnesium sheets, which are very strong and deteriorate less, are provided as a heat conductive layer on upper and lower sides of the heating wires. [8] However, such a configuration is disadvantageous because a lot of time, cost and effort are required to arrange the heating wires between upper and lower magnesium sheets, and furthermore, maintenance, repair and replacement of the completed products are burdensome.

[9] Therefore, there is a need for the development of a heating pad, which is capable of being realized through a simple manufacturing process at decreased manufacturing costs and facilitates the maintenance, repair and replacement thereof. Disclosure of Invention Technical Problem

[10] Accordingly, the present invention has been made keeping in mind the above problems occurring in the related art, and provides a heating board, which is manufactured through a simple manufacturing process at decreased manufacturing cost, facilitates maintenance, repair and replacement thereof, and is realized in a thin film form corresponding to the form of use of conventional boards, thus exhibiting wide applicability as various interior materials in diverse fields. Technical Solution

[11] To this end, according to the present invention, there is provided an impregnated heating sheet, comprising carbon paper for generating heat using electrical resistance and copper foil strips provided to the carbon paper to apply electricity to the carbon paper, wherein the carbon paper and the copper foil strips are subjected to LPM (low pressure melamine impregnation) using a thermosetting resin including melamine.

Advantageous Effects

[12] According to the present invention, in the impregnated heating sheet, the heating board, and the manufacturing method thereof, the impregnated heating sheet and the heating board can be more simply and inexpensively manufactured by subjecting carbon paper for generating heat using electrical resistance and copper foil strips to melamine impregnation of thermosetting resin, thus realizing technical effects so as to increase product competitiveness.

[13] In addition, according to the present invention, in the impregnated heating sheet, the heating board, and the manufacturing method thereof, the heating board can be relatively simply integrated, compared to conventional boards. In the course of use of the completed product, the maintenance, repair and replacement of the product can be further facilitated, thus realizing technical effects so as to increase convenience of use.

[14] In addition, according to the present invention, in the impregnated heating sheet, the heating board, and the manufacturing method thereof, it is not difficult to exhibit the performance of the inventive heating board even without additional dielectric or waterproofing treatment, compared to conventional heating boards using hot wires or planar heaters, thus realizing technical effects so as to decrease additional processes and costs after the manufacturing process.

[15] In addition, according to the present invention, in the impregnated heating sheet, the heating board, and the manufacturing method thereof, the heating layer can be manufactured to be thinner, thus realizing technical effects so as to increase applicability not only in product fields (floor materials, furniture materials, other interior materials) to which conventional board products are applied, but also in decoration fields. Brief Description of the Drawings

[16] FIG. 1 is a perspective view illustrating the heating board according to a first embodiment of the present invention;

[17] FIG. 2 is a bottom plan view schematically illustrating the impregnated heating sheet according to the present invention;

[18] FIG. 3 is a perspective view illustrating the heating board according to a second embodiment of the present invention;

[19] FIG. 4 is a perspective view illustrating the heating board according to a third embodiment of the present invention;

[20] FIG. 5 is a flowchart illustrating an embodiment of the process of manufacturing the heating board according to the present invention; and

[21] FIG. 6 is a flowchart illustrating another embodiment of the process of manufacturing the heating board according to the present invention.

[22] <Description of the Reference Numerals in the Drawings>

[23] 110: woody board 120: impregnated heating sheet

[24] 122: carbon paper 124: copper foil strip

[25] 130a, 130b: impregnated thermosetting resin paper layers

[26] 140: 1^st functional layer 150: 2° functional layer

Best Mode for Carrying Out the Invention

[27] According to an aspect of the present invention for accomplishing the technical problem as above, an impregnated heating sheet may comprise carbon paper for generating heat using electrical resistance; and copper foil strips provided to the carbon paper to apply electricity to the carbon paper, wherein the carbon paper and the copper foil strips are subjected to low pressure melamine impregnation using a thermosetting resin including melamine.

[28] In addition, according to another aspect of the present invention, an impregnated heating sheet may comprise kraft paper; carbon paper for generating heat using electrical resistance; and copper foil strips provided to the carbon paper to apply electricity to the carbon paper, wherein the kraft paper, the carbon paper, and the copper foil strips are subjected to high pressure melamine impregnation using a ther- mosetting resin including melamine.

[29] In addition, according to a further aspect of the present invention, an impregnated heating sheet may comprise carbon paper for generating heat using electrical resistance; and copper foil strips provided to the carbon paper to apply electricity to the carbon paper, wherein the carbon paper and the copper foil strips are subjected to low pressure melamine impregnation using an impregnated thermosetting resin paper including melamine.

[30] The carbon paper preferably comprises carbon powder or carbon-coated glass fiber.

[31] A heating board preferably comprises a woody board; and the above impregnated heating sheet, which is laminated on the bottom surface of the woody board through hot pressing.

[32] The heating board may further comprise a first functional layer laminated on the bottom surface of the impregnated heating sheet through hot pressing, in order to enhance the water resistance or mechanical strength of the heating board.

[33] The heating board may further comprise a second functional layer laminated on the bottom surface of the impregnated heating sheet, in order to enhance a sound absorption function, a sound isolation function, or a dielectric function.

[34] In addition, according to yet another aspect of the present invention, a method of manufacturing a heating board may comprise attaching copper foil strips to carbon paper; impregnating the carbon paper and the copper foil strips with a thermosetting resin including melamine, thus manufacturing an impregnated heating sheet; and laminating the impregnated heating sheet on the bottom surface of a woody board through hot pressing, thus forming the heating board.

[35] In addition, according to still another aspect of the present invention, a method of manufacturing a heating board may comprise attaching copper foil strips to carbon paper; overlaying top and bottom surfaces of the carbon paper, having the copper foil strips attached thereto, with impregnated thermosetting resin paper layers including melamine; and disposing the carbon paper and the copper foil strips overlaid with the impregnated thermosetting resin paper layers on the bottom surface of a woody board, and then conducting lamination through hot pressing, thus forming the heating board.

[36] In the above method, forming the heating board may further comprise forming a first functional layer on the bottom surface of the heating board through hot pressing, in order to enhance water resistance or mechanical strength.

[37] In the above method, forming the heating board may further comprise forming a second functional layer on the bottom surface of the heating board, in order to enhance a sound absorption function, a sound isolation function, or a dielectric function. Mode for the Invention [38] The preferred embodiments of the present invention are incorporated into the detailed description and the drawings.

[39] The advantages and features of the present invention and the methods for achieving them will be more clearly understood from the following detailed description, taken in conjunction with the accompanying drawings. However, the present invention is not limited to the embodiments disclosed below, but may be realized in various forms. The present embodiments are provided to complete the disclosure of the present invention and to make the scope of the invention known to those ordinarily skilled in the art, but the present invention is defined only by the scope of claims. Throughout the description, like reference numerals refer to like elements.

[40] In the drawings, FIG. 1 is a perspective view illustrating the heating board according to a first embodiment of the present invention, FIG. 2 is a back plan view schematically illustrating the impregnated heating sheet according to the present invention, FIG. 3 is a perspective view illustrating the heating board according to a second embodiment of the present invention, FIG. 4 is a perspective view illustrating the heating board according to a third embodiment of the present invention, FIG. 5 is a flowchart illustrating an embodiment of the process of manufacturing the heating board according to the present invention, and FIG. 6 is a flowchart illustrating another embodiment of the process of manufacturing the heating board according to the present invention.

[41] With reference to FIGS. 1 to 4, the impregnated heating sheet and the heating board according to the preferred embodiments of the present invention are described.

[42] FIG. 1 is a perspective view illustrating the heating board, according to the first embodiment of the present invention.

[43] As illustrated in FIG. 1, the heating board of the present invention comprises a woody board 110, an impregnated heating sheet 120 laminated on the bottom surface of the woody board, and a first functional layer 140 laminated on the bottom surface of the impregnated heating sheet.

[44] Examples of the woody board 110 include fiber boards (e.g., HDF (high density fiber board), MDF (medium density fiber board), LDF (low density fiber board), etc.), particle boards (e.g., OSB (oriented stand board), etc.), and plywood. In addition, it will be apparent that various materials similar thereto may be used depending on the types of product to which the heating board of the present invention is applicable.

[45] FIG. 2 illustrates the impregnated heating sheet 120, according to the present invention.

[46] The impregnated heating sheet 120 comprises carbon paper 122 for generating heat using electric resistance, and one or more copper foil strips 124 attached to appropriate portions of the bottom surface of the carbon paper 122 in order to apply electricity to the carbon paper 122. Preferably, as illustrated in FIG. 2, two copper foil strips 124 are attached to the bottom surface of the carbon paper 122 such that they are disposed parallel to each other with a predetermined interval therebetween in a longitudinal direction.

[47] The carbon paper 122 and the copper foil strips 124 are impregnated with a thermosetting resin including melamine. As such, the impregnated heating sheet 120 may be embodied in some forms depending on the melamine impregnation method. In a first form, carbon paper 122 and copper foil strips 124 attached to the carbon paper 122 are subjected to LPM (low pressure melamine impregnation) using a thermosetting resin including melamine.

[48] As such, LPM is an adhesion process, which is conducted at a lower pressure (about

10-20 kgf/D) than HPM (high pressure melamine impregnation), described below. Such a process enables adhesion through hot pressing even without the additional use of an adhesive because the impregnated heating sheet is thin.

[49] In a second form, additional kraft paper (not shown), carbon paper 122, and copper foil strips 124 are subjected to HPM using a thermosetting resin including melamine, thus forming an impregnated heating sheet 120. The LPM or the HPM is typically known in the art, and thus a detailed description thereof is omitted.

[50] In a third form, carbon paper 122 and copper foil strips 124 are subjected to LPM using impregnated thermosetting resin paper (not shown), including melamine, thus forming an impregnated heating sheet 120. The impregnated thermosetting resin paper including melamine indicates a thermosetting resin member in a paper form.

[51] The carbon paper 122 functions to generate heat using electrical resistance. To this end, the carbon paper 122 may be composed of carbon powder or carbon-coated glass fiber.

[52] In this way, the woody board 110 and the impregnated heating sheet 120 may be laminated together through hot pressing.

[53] According to the first embodiment of the present invention, in addition to the woody board 110 and the impregnated heating sheet 120, a first functional layer 140 may be further laminated on the bottom surface of the heating board. The first functional layer 140 may be additionally formed to improve the water resistance or the mechanical strength of the heating board of the present invention. The first functional layer 140 may be laminated through hot pressing, which is the same as the process of laminating the woody board 110 and the impregnated heating sheet 120.

[54] In addition to the first embodiment, according to the second embodiment illustrated in FIG. 3, a second functional layer 150 is further provided between the heating board and the first functional layer 140. The second functional layer 150 is additionally formed to enhance the sound absorption function, sound isolation function, or dielectric function of the heating board of the present invention.

[55] Unlike the first and second embodiments, according to the third embodiment illustrated in FIG. 4, both surfaces of the carbon paper 122 having copper foil strips 124 disposed to the bottom of the carbon paper are overlaid with impregnated thermosetting resin paper layers 130a, 130b including melamine, after which a woody board 110 is disposed thereon and then lamination is conducted through hot pressing, thus producing a heating board.

[56] The third embodiment is advantageous in that it involves a relatively simple process, because the impregnated thermosetting resin paper layers 130a, 130b including melamine in a paper form are simply overlaid and laminated to thus form the heating board, unlike the first and second embodiments, in which the impregnated heating sheet 120 is previously formed through impregnation.

[57] When electricity flows to the copper foil strips 124 via electrical wires 20 from a power source 10, electrical resistance occurs on the carbon paper 122 to which the copper foil strips 124 are attached, so that the carbon paper 122 generates heat using such electrical resistance. Further, the heating board, composed of such an impregnated heating sheet 120, realizes a warming function.

[58] Turning now to FIG. 5, an embodiment of the method of manufacturing the heating board according to the present invention is illustrated, by which copper foil strips are first attached to carbon paper (S210). The carbon paper generates heat using electrical resistance, and, in order to apply electricity to such carbon paper, the copper foil strips are attached thereto. The configuration of the copper foil strips to be attached may be appropriately modified depending on the type of application product thereof.

[59] Thereafter, the carbon paper and the copper foil strips are impregnated with a thermosetting resin including melamine to thus manufacture an impregnated heating sheet (S230). The melamine resin impregnation method is largely divided into two types, in one of which the carbon paper and the copper foil strips are subjected to LPM using a thermosetting resin including melamine, thus manufacturing the impregnated heating sheet, and in the other one of which additional kraft paper, the carbon paper, and the copper foil strips are subjected to HPM, thus manufacturing the impregnated heating sheet. As such, the LPM or the HPM is typically known in the art, and thus a detailed description thereof is omitted.

[60] Thereafter, the impregnated heating sheet is laminated on the bottom surface of a woody board through hot pressing to thus form a heating board (S250). Through this procedure (S250), the formation of a basic heating board is completed.

[61] After the completion of the formation of the basic heating board, in order to impart a sound absorption function, a sound isolation function, or an insulating function, a procedure (S270) of forming a second functional layer on the bottom surface of the heating board formed in the previous procedure (S250) may be performed, and furthermore, in order to enhance water resistance or mechanical strength, a procedure (S290) of forming a first functional layer on the bottom surface of the heating board may be performed.

[62] In addition, FIG. 6 illustrates an another embodiment of the method of manufacturing the heating board according to the present invention, comprising attaching copper foil strips to carbon paper (S310), overlaying top and bottom surfaces of the carbon paper having the copper foil strips attached thereto with impregnated thermosetting resin paper layers including melamine (S330), disposing the carbon paper and the copper foil strips overlaid with the impregnated thermosetting resin paper layers on the bottom surface of a woody board and then conducting lamination through hot pressing (S350), forming a second functional layer on the bottom surface of the heating board obtained through impregnation in the previous procedure in order to impart a sound absorption function, a sound isolation function, or an insulating function (S370), and forming a first functional layer on the bottom surface of the heating board in order to enhance water resistance or mechanical strength (S390).

[63] In such another embodiment, the configuration of the copper foil strips may be the same as or similar to that in the aforementioned embodiment, but the heating board comprising the woody board, the carbon paper, and the copper foil strips may be advantageously constructed through one hot pressing process, thanks to the use of the impregnated thermosetting resin paper including melamine.

[64] Thereby, the heating board, which is applicable to all products (floor materials, furniture materials, and other interior materials), can be manufactured through a simpler process at lower cost than in any other conventional method.

[65] Although the preferred embodiments of the present invention have been disclosed for illustrative purposes with reference to the examples depicted in the drawings, those ordinarily skilled in the art will appreciate that various modifications, additions and substitutions are possible.

[66] Thus, the technical concept of the invention is limited only to the scope of the invention as defined by the accompanying claims. Industrial Applicability

[67] According to the present invention, an impregnated heating sheet, a heating board, and a manufacturing method thereof can be applied to a warming system for use in various building facilities.

Claims

[1] An impregnated heating sheet, comprising: a carbon paper for generating heat using electrical resistance; and copper foil strips provided to the carbon paper to apply electricity to the carbon paper, wherein the carbon paper and the copper foil strips are subjected to low pressure melamine impregnation using a thermosetting resin including melamine.

[2] An impregnated heating sheet, comprising: a kraft paper; a carbon paper for generating heat using electrical resistance; and copper foil strips provided to the carbon paper to apply electricity to the carbon paper, wherein the kraft paper, the carbon paper, and the copper foil strips are subjected to high pressure melamine impregnation using a thermosetting resin including melamine.

[3] An impregnated heating sheet, comprising: a carbon paper for generating heat using electrical resistance; and copper foil strips provided to the carbon paper to apply electricity to the carbon paper, wherein the carbon paper and the copper foil strips are subjected to low pressure melamine impregnation using an impregnated thermosetting resin paper including melamine.

[4] The impregnated heating sheet according to any one of claims 1 to 3, wherein the carbon paper comprises carbon powder or carbon-coated glass fiber.

[5] A heating board, comprising: a woody board; and the impregnated heating sheet of any one of claims 1 to 3, which is laminated on a bottom surface of the woody board through hot pressing.

[6] The heating board according to claim 5, further comprising a first functional layer laminated on a bottom surface of the impregnated heating sheet through hot pressing, in order to enhance water resistance or mechanical strength of the heating board.

[7] The heating board according to claim 5, further comprising a second functional layer laminated on a bottom surface of the impregnated heating sheet, in order to enhance a sound absorption function, a sound isolation function, or a dielectric function.

[8] A method of manufacturing a heating board, comprising: attaching copper foil strips to a carbon paper; impregnating the carbon paper and the copper foil strips with a thermosetting resin including melamine, thus manufacturing an impregnated heating sheet; and laminating the impregnated heating sheet on a bottom surface of a woody board through hot pressing, thus forming the heating board.

[9] A method of manufacturing a heating board, comprising: attaching copper foil strips to a carbon paper; overlaying top and bottom surfaces of the carbon paper, having the copper foil strips attached thereto, with impregnated thermosetting resin paper layers including melamine; and disposing the carbon paper and the copper foil strips overlaid with the impregnated thermosetting resin paper layers on a bottom surface of a woody board, and then conducting lamination through hot pressing, thus forming the heating board.

[10] The method according to claim 8 or 9, wherein the forming the heating board further comprises forming a first functional layer on a bottom surface of the heating board through hot pressing, in order to enhance water resistance or mechanical strength.

[11] The method according to claim 8 or 9, wherein the forming the heating board further comprises forming a second functional layer on a bottom surface of the heating board, in order to enhance a sound absorption function, a sound isolation function, or a dielectric function.