CA1208268A - Self-regulating heaters - Google Patents

Abstract

SPECIFICATION FOR PATENT APPLICATION

Title "ELONGATE HEATERS"
Applicant Raychem Corporation, a corporation organized according to the laws of the State of California, U.S.A. 7 of 300 Constitution Drive, Menlo Park, California 94025, U.S.A.
Inventor Hundi Panduranoa Kamath, a citizen of India, of 879 Lockhaven Drive, Los Altos, California 94022 Convention Priority to be claimed U.S. Serial No. 380,400, filed 21 May 1982 by the inventor named above.

ABRIDGEMENT

Elongate electrical heaters which comprise at least two elongate conductors and at least one elongate resistive heating strip which contacts the conductors alternately as it progresses down the length of the heater, and which is preferably composed of a conductive polymer, particularly a PTC conductive polymer. The conductors can be separated from each other by an insulating strip, with the heating strip being wrapped around the conductors and the insulating strip.
Alternatively the conductors can be wrapped around a core comprising the heating strip and an insulating strip. The junctions between the conductors and the heating strip are preferably coated with a low resistivity conductive polymer composition. Figure 1 shows a preferred heater.

Description

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_z _ This invention relates to elongate electrical strip heaters.

Many elongate electrical heaters, e.g. for heating pipes, tanks and other apparatus in the chemical process industry, comprise two (or more) relatively low resistance conductors which are connected to the power source and run the length of the heater, with a plurality of heating elements connected in parallel with each other between the conductors (also referred to in the art as electrodes.) In conventional conductive polyrner strip heaters, the heating elements are in the form of a continuous strip of conductive polymer in which the conductors are embedded.
In other conventional heaters, known as zone heaters, the heating elements are one or more resistive metallic heating wires. In zone heaters, the heating wires are wrapped around the conductors, which are insulated except at spaced-apart points where they are connected to the heating wires. The heating wires contact the conductors alternately and make multiple wraps around the conductors between the connection points. For many uses, elongate heaters are preferably self-regulating. This is achieved9 in conventional conductive polymer heaters, by using a continuous strip of conductive polymer which exhibits PTC
behavior. It has also been proposed to make zone heaters self-regulating by connecting the heating wire(s) to one or both of the conductors through a connecting element composed of a ceramic PTC material.

Elongate heaters of various kinds, and conductive polymers for use in such heaters, are disclosed in U. S. Patents Nos. 2,952,761, 2,978,665, 3,243,753, 3,351,882, 3,571,777, 3,757,086, 3,793,716, 3,823,217, 3,858,144, 3,861,029, 4,017,715, 4,072,848, 4,085,286, ~208Z6~

4,117,312, 4,177,376, 4,177,446, 4,188,276, 4,237,441, 4,242,573, 4,246,468, 4,250,400, 4,255,6g8, 4,271,350, 4,272,471, 4,309,596, 4,309~597, 4,314,230, 4,315,237, 4,318,881, 4,327,351, 4,330,70~, 4,334,148, 4,334,351 and 4,361,799; J. Applied Polymer Science 19, 813-815 (1975), Klason and Kubat; Polymer Engineering and Science 18, 649-653 (1978), Narkis et al; German OLS Nos. 2,634,999

2,755,077, 2,746r602, 2,755,076, 2,821,799 and 3,030,799; U.K.
Patents No. 1,600,256 and 1,~05,005.
According to the present invention, there is provided an elongate electrical heater which comprises (1) first and second elongate, spaced-apart, conductors which can be connected to a source of electrical power, and (2) an elongate resistive heating strip which (i) comprises an elongate resistive heating component which is composed of a conductive polymer exhibiting PTC behavior, and (ii) is in electrical contact alternately with the first conductor and the second conductor at contact points which are longitudinally spaced apart along the length of the strip and along the length of each of the conductors.
The heater of the invention is distinguished from con-ventional conductive polymer strip heaters and conductive polymer heaters as disclosed in U.S. Patents Nos. 4,271,350 and 4!309~597 by the requirement that the contact points are longitudinally spaced apart along the length of the heating strip and along the length of each of the conductors. This is a difference which can , `

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result in very important advantages. One advantage results from the fact that elongate conductive polymer components are generally produced by methods which involve continuously shaping the conductive polymer composition into a strip, e.g., by melt-extrusion or by deposition onto a substrate. It has been found that the uniformity of the resistance of such a strip is greater in the longitudinal (or "machine") direction (e.g., khe direction of extrusion) than in the transverse direction. In the known conductive polymer heaters, current passes through the conductive polymer mainly or exclusively in the transverse direction, whereas in the strip heaters of the invention, the current usu-ally passes through the conductive polymer mainly or exclusively in the longitudinal direction. In consequence the new heaters can have improved power output and voltage stability. Another advantage is that if an arcing fauIt occurs in a known conduc-tive polymer heater, the fauIt can be propagated along the whole length of the heater, and thus render the whole heater inoperative.
On the other hand, if such a fauIt occurs in a heater of the invention, it is difficult or impossible for it to propagate along the heater, because there is no continuous interface between the conductive polymer component of the heating strip and the conductors.
The heater of the invention is a self-regulating heater because of the use of a conductive polymer which -5- ~20826~ MP0821/A

exhibits PTC behavior. In this specification, a component is said to exhibit PTC behavior if its resistance increases by a factor of at least about 2 over a temperature range of 100C. A more rapid increase in resistance is preferred, for example an increase in resistance by a factor of at least 2.5 over a temperature range of 14C or by a factor of at least 10 over a temperature range of 100C, and preferably both. Such heaters are distinguished from known conductive polymer heaters by the requirement for spaced-apart contact points on the strip, as just described, and from self-regulating zone heaters as disclosed in U.S.
Patent No. 4,1i7,312 by the fact that the heating strip comprises a continuous elongate element which exhibits PTC behavior, whereas in Patent No. 4,117,312 it is only the connecting element which exhibits PTC behaviorO
This difference results in important advantages, because the use of a small PTC connecting element as described in Patent No. 4,117,312 results in very high power densities in the connecting element, with conse-quent danger of damage to the element or its connections to the bus wire and the heating wire.
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In a ~*ih~ embodiment of the invention, the heating strip (a) has a resistance at 23C of at least lû, preferably at least 100, ohms per cm length and a cross-sectional area of at least 0.0001 cm2, preferably at least 0.001 cm2, and (b) makes electrical contact with each conductor each time the heating strip crosses the conductor. Such heaters are distinguished from known conductive polymer heaters by the requirement for spaced-apart contact points on the strip, as just described, and from self-regulating zone heaters as disclosed in U.S.
Patent No. 4,117,}12 by the resistance and cross-sectional ~LZ0~32~

area requirements and the requirement for electrical contact at each crossing point. In this way a great disadvantage of known zone heaters is avoided, namely the necessity for multiple wraps of the heating wire between contact points in order to obtain the necessary level of resistance, with the consequent need to insu-late the conductors except at the contact points.
A preferred class of heaters of the invention comprises a PTC conductive polymer heating strip wrapped around a pair of conductors and making contact with each of the conductors at each wrapping point, the heating strip having for example a cross-sectional area of 0.002 to 0.08 cm2 and a resistance of 100 to 5,000 ohms per cm length. Another class of heaters of the inven-tion comprises two or three conductors wrapped around a central element which comprises an elongate PTC conductive polymer heating strip and an elongate insulating element, the conductors making contact with the PTC element at each wrapping point, the heating strip having for example a cross-sectional area of 0.002 to 0.6 cm and a resistivity at 23C of 1 to 10,000 ohm.cm, prefer-ably 1 to 100 ohm~cm for heaters to be powereed by low voltage sources and 100 to 5,000 ohm.cm for heaters to be powered by con-ventional line voltages.
In addition to the advantages already noted, the novel heaters offer the considerable benefit that excellent conductive polymer heaters can be made from polymers which cannot be satis-factorily used in conventional heaters, in particular tetrafluor-ethylene/perfluoroalkoxy polymers, whose high melting point makes them particularly valuable. Also, the absence of a continuous metal/conductive polymer - ' 3z615 interface renders the heaters less liable to failure in the presence of moisture. Finally, h~aters of different powers can easily be made from the same components merely by changing the geometry of the heaters.

The novel heaters are preferably self-regulating heaters comprising a heating strip which exhibits PTC
behavior, particularly a heating strip comprising a component which runs the length of the heating strip and which exhibits PTC behavior, when its resistance/temperature characteristic is measured in the absence of the other components of the heater, particularly a heating strip comprising a PTC conductive polymer component. However, the heating strip can also exhibit PTC behavior as a result (at least in part) of constructing and arranging the heater so that, when the heater increases in temperature, the heating strip undergoes a reversible physical change (e.g. elastic stretching due to thermal expansion of part of the heating strip and/or other components of the heater) which increases its resistance. When (as is usually the case) the heater comprises an insulating polymeric jacket, pressure exerted by this jacket can (but usually does not) influence the PTC behavior of the strip.

There are a wide variety of relative configurations of the heating strip(s) and the conductors which will give rise to the desired spaced-apart contact points.
Generally it will be convenient for the conductors to be straight and the heating strip(s) to follow a regular sinuous path, or vice-versa. The path may be _ for example generally helical (including generally 38~t;8 -8- MP0~21/A

circular and flattened circular helical), sinusoidal or Z-shaped. However, it is also possible for both the conductors and the heating strip(s) to follow regular sinuous paths which are different in shape or pitch or of opposite hand, or for one or both to follow an irregular sinuous path. In one preferred configuration7 the heating strip is wrapped around a pair of straight parallel conductors, which may be maintained the desired distance apart by means of a separator strip. In another configuration the heating strip is wrapped around a separator strip and the wrapped strip is then contacted by straight conductors. In another preferred configuration, the conductors are wrapped around one or more straight heating strips and one or more straight insulating cores;
the core may be (or contain) the substrate to be heated, eg. an insulated metal pipe or a pipe composed of insulating material. In another configuration, the conductors are wrapped around an insulating core and are then contacted by straight heating strips. It is often convenient for the wrapped element to have a generally helical configur-ation, such as may be obtained using conventional wire-wrapping apparatus. However, other wrapped configurations are also possible and can be advantageous in ensuring that substantially all the current passing through the heating strip does so along the axis of the strip; for example when the conductors are wrapped around the heating strip(s), they can be wrapped so that their axes, as they cross the heating strip(s), are substantially at right angles to the axis of the heating strip, with the progres-sion of the conductors down the length of the strip beingmainly or exclusively achieved while the conductors are not in contact with the heating strip. In the various 08Z~3 -9- l~P0821/A

wrapped configurations, the wrapped component can for example follow a path which is generally circular, oval or rectangular with rounded corners. For the best heat transfer to a substrate, it is often preferred that the heater has a shape which is generally rectangular with rounded corners.

It is also possible for th0 heating strip to be laid out, eg. through use of a vibrating extrusion head, in a regular sinuous pattern, either on top of the conductors or on a support, with the conductors then being applied to the laid-out heating strip. If the heating strip is laid out on top of the conductors, further conductors can be placed on top of the original ones, thus sandwiching the heating strip in the middle of a two part conductor.

The novel heaters generally contain two elongate conductors which are alternately contacted by the heating strip. However, there can be three or more conductors which are sequentially contacted by the heating strip, provided that the conductors are suitably connected to one or more suitable power sources. When three or more conductors are present, they can be arranged so that different power outputs can be obtained by connecting different pairs of conductors to a single phase or two phase power source. When three-conductors are present they can be arranged so that the heater is suitable for connection to a three phase power source. The conductors are usually parallel to each other. The conductors are preferably of metal, eg. single or stranded wires, but other materials of low resistivity can be used. The shape of the conductor at the contact points with the heating strip can influence the electrical characteristics of the junctions. Round wire conductors are often convenient and give good results, but conductors of other cross-sections (for example flat metal strips) can also be used. The conductors can be contacted by the heating strip directly or through an intermediate conductive component; for example the conductors can be coated with a layer of conductive material, eg. a low resistivity ZTC conductive polymer composition, before being contacted by the heating strip.

The conductors must remain spaced apart from each other, and for this reason the novel heaters preferably comprise at least one separator strip which lies between the conductors. The separator strip is preferably one which will remain substantially unchanged during preparation and use of the heater, except for thermal expansion and contraction due to temperature changes;
such thermal expansion and contraction can be significant in influencing PTC behavior, especially when the separator strip comprises a metal insert, particularly when the insert is a conductor which generates heat by I2R
heating during use of the heater, as further described below. The separator strip will usually have the same general configuration as the conductors, egO if they are straight, the separator is straight, and if they are wrapped, the separator is wrapped with them.

In one class of heaters, the separator strip electrically insulates the conductors from each other so that, when the conductors are connected to a po~er source, all the current passing between the conductors passes through the heating strip or strips.

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Such a separator strip can consist essentially of electrically insulating material. However, the properties of the heaters are improved if the separator has good thermal conductivity, and for this reason (since most materials of good thermal conductivity are also electrical conductors) the separator strip can comprise electrically conductive material, eg. metal, surrounded by insulating material. The insulating material is generally a polymeric material, preferably one containing a thermally conductive material.

In another class of heaters, the separator strip is composed of electrically resistive material and thus provides an additional source of heat when the .conductors are connected to a power source. In this class of heaters, the heater preferably comprises a second resistive heating strip which is composed of a conductive polymer composition and which is in continuous electrical contact with the conductors. The resistance and resistance/
temperature characteristics of such a separator strip can be correlated with those of the heating strip or strips to produce desired results, as further discussed below. In such heaters there will usually be a continuous interface between the conductors and the conductive separator strip and at least a substantial proportion of the current which passes through the separator strip will do so in a transverse direction.

The conductors can also be maintained in desired positions by means of insulating material which also provides an insulating jacket around the conductors and heating strip or strips. The jacket can for example be in the form of a tube which has been drawn down around a pair of conductors having a heater strip wrapped around them.

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In addition to the conductors which are contacted by the heating strip, the novel heaters can contain one or more addi-tional elongate conductors which are insulated from the other elec-trical components and which can be used to connect the heater in the novel way disclosed in Canadian patent application Serial No.
425,959 filed on April 15, 1983 in the name of Raychem Corporation, and optionally to provide an auxiliary source of heat. One or more of such conductors can be embedded in an insulating separator strip.
The novel heaters contain at least one heating strip which contacts the elongate conductors. In many cases, use of a single heating strip gives excellent results. However, two or more heating strips can be used, in which case the heating strips are usually, but not necessarily, parallel to each other along the length of the heater; the heating strips are preferably the same~
but can be different; for example, one of the heating strips can be PTC with one Ts and another can be ZTC or PTC with a different Ts. For a particular heating strip, heaters of the same power out-put can be obtained by a single strip wrapped at a relatively low pitch (a high number of turns per unit length) or by a plurality of parallel heating strips wrapped at a relatively high pitch; use of a plurality of strips results in a lower voltage stress on the heating strip.
The strip or strips are arranged so that successive con-tact points on each conductor are spaced apart from each other.
If desired, one or more insulating members can be wrapped with one or more heating strips so as to maintain desired spacing between adjacent wraps of the heating strip or strips.

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The heating strip can have any configuration which results in the desired alternate contact of the heating strip with the conductors. However, excessive bending of the heater strip often has an adverse effect on its electrical and/or physical propertiesl Consequently it is preferred that the heating strip is in a configuration such that most, and preferably substantially all~ of the parts of the heating strip which are electrically active (i.e. which make a useful contribution to the heat output of the heater) are not e~cessively bent, eg. have a radius of curvature at all points in the substantial current path which is at least ~ times, preferably at least 5 times, especially at least 10 times its diameter.

The heating strip preferably comprises a conductive polymer component which runs the length of the heating strip, and the invention will be chiefly described by reference to such a strip. However, it is to be under-stood that the invention includes any kind of resistive heating strip, for example a heating strip which comprises conductive ceramic material, e.g. desposited on single filament or multifilament yarn.

The heating strip can consist essentially of a single conductive composition, or it can comprise (a) a first component which runs the length of the heating strip and (b) a second component which runs the length of the heating strip and which is composed of a conductive composition, at least a part of the second component lying between the first component and the conductors. The first component can be electrically conducting, eg. be composed of a conductive polymer composition, or electrically insulating, eg. be composed of glass or other ceramic ~Z()8Z6~3 material or natural or synthetic polymeric material. The first and second components are preFerably distinct from each other, eg. a first component which provides the core and a second component in the form of a jacket which surrounds the core. However, the second component can also be distributed in a first component which is preferably an electrical insulator, eg. a glass filament yarn which has been passed through a liquid conductive composition eg. a solvent-based composition. When the first and second components are both composed of a conductive polymer composition, the first component is preferably composed of a conductive polymer composition which exhibits PTC behavior with a switching temperature below the switching temperature of the second component.

An alternative way of providing the desired PTC
behavior (or of modifying PTC behavior resulting from use of a PTC heating strip) is to construct the heater so that when the heater increases in temperature, the length of the conductive polymer component of the heating strip is caused to change by an amount different from its normal thermal expansion or contraction. For example the heater can contain conductors or a separator strip comprising a material having a high coefficient of thermal expansion, or the heating strip can comprise a first component composed of a material having a high coefficient of thermal expansion. In this way, for example, a heating strip comprising a ZTC conductive polymer component can be caused to exhibit PTC behavior. This is useful because it makes it possible to use ZTC conductive polymer compositions if this is desirable, eg. for particular physical properties.
It is of course important that any stretching of the heating strip should be below its elastic limit, and for this reason the heating strip may comprise a first component which is composed of an elastomeric material.

12Q13Z6~3 As briefly noted above, the novel heaters can contain a separator strip which provides a second resistive heating strip, which is composed of a second conductive polymer composition and which is in continuous electrical contact with the conductors. The second conductive polymer composition can exhibit PTC behavior~
with a switching temperature which is above or below the switching temperature, Ts, of a PTC conductive polymer in the wrapped heating strip. Alternatively the second conductive polymer composition can exhibit ZTC behavior at temperatures below Ts and can provide a current path between the conductors whose resistance (a) is higher than the resistance of the current path along the first heating strip when the heater is at 23C and (b) is lower than the resistance of the current path along th0 first heating strip at an elevated temperature.

The production of conductive polymer heating strips for use in the present invention can be effected in any convenient way, eg. by melt-extrusion~ which is usually preferred, or by passing a substrate through a liquid (eg.
solvent-based) conductive polymer composition, followed by cooling or solvent-removal~ When producing the strip by melt-extrusion, the draw-down ratio has an important effect on the electrical properties of the heater. Thus use of higher draw-down ratios generally increases the resistance uniformity of the strip but reduces the extent of any PTC effect. The optimum draw-down ratio depends on the particular conductive polymer composition.

The thickness of the conductive polymer in the 3û heating strip is preferably 0~025 to 0.2 cm, e.g. 0.06 to 0.14 cm. The strip can be of round or other cross-section; for example the heater strip can be in the form of a flat tape.

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The conductive polymer heating strips can optionally be cross-linked, eg. by irradiation, either before or after they are assembled into heaters.

A very wide variety of conductive polymers can be S used in the heating strips, for example compositions based on polyolefins, copolymers of olefins and polar comonomers, fluoropolymers and elastomers9 as well as mixtures of two or more of these. Suitable conductive polymers are disclosed in the publications referenced above. The resistivity of such conductive polymers at 23C is usually 1-100,000, preferably 100 to 5,000, particularly 200 to 3,000, ohm.cm. The conductive polymer can be PTC or ZTC, the term ZTC being used to mean that the conductive polymer does not exhibit PTC behavior in the normal temperature range of operation of the heater (i.e. including NTC behavior).

The novel heaters are preferably made by wrapping the heating strip tor strips) around the conductors, or vice versa, while maintaining the conductors the desired distance apart, either through use of a separator strip or otherwise. When using a PTC heating strip, care should be taken to make use of a wrapping tension which provides a suitable compromise between the desire to bring the heating strip into good contact with the con-ductors and the desire to avoid stretching the strip,which usually causes undesirable changes in its resistance and/or resistance/temperature characteristics. It is preferred to coat the junctions between the conductors and the heating strip with a low resistivity (preferably less than 1 ohm.cm) composition, e.g. a conductive polymer composition (eg. a solvent-based composition which is 31 ;~V~326~3 allowed to dry after it has been applied), so as to reduce contact resistance. Such a coating can also help to ensure that-substantially all the current passes only through the substantially straight portions of the heating strip. Care should be taken, however, to ensure that the coating does not extend any substantial distance up the heating strip beyond the junctions, since this reduces the effective (heat-generating) length of the heating strip. Similar low resistance coatings can lû be applied to the contact points by other methods, eg. by flame-spraying or vapor deposition of a metal~
.

ûther methods which can be used to reduce contact resistance include pre-heating the conductors before they are contacted by the heating strip, and heat-treating conductive polymer adjacent the conductors after the heater has been assembled~ The whole heater can be heated or localized heating can be effected eg. by powering the conductors.

A particular advantage of the present invention is that heaters having different electrical characteristics can be easily produced from a single heating strip. For example, a range of very different heaters, eg. of different power outputs, can easily be produced merely by changing the pitch used to wrap the heating strip or the conductors, and/or by using two or more heating strips, and/or by changing the distance between the conductors. The pitch of the heating strip is preferably 0.2û to 2.5 cm and the distance between the conductors is preferably 0.5 to 1.5 cm. These different variables can be maintained sub-stantially constant or one or more of them can be variedperiodically to produce a heater having segments of di~ferent power outputs. Further, if desired, the pitch ~Z()82~
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of the wrapped component and/or the distance between the conductors can be varied gradually to compensate for changes in the potential difference between the conductors at different distances from the power source.

In assembling the novel heaters, the presence of voids is preferably avoided, and a polysiloxane grease or other thermal conductor can be used to fill any voids.

Referring now to the drawing, Figures 1-18 are plan and cross-sectional views of heaters of the invention and Figures 19-22 are cross-sectional views of heating strips suitable for use in the invention~ The reference numerals in the Figures denote the same or similar com-ponents. Thus numerals 1, 2, lA and 2A denote he~ting strips; 11 denotes a first conductive polymer component of a heating strip; 12 denotes a second conductive polymer component of a heating strip; 13 denotes an insulating component of a heating strip; 14 denotes a multifilament yarn composed of an insulating material; 3, 4, 5 and 5A
denote round wire conductors; 6 denotes a separator strip which maintains the conductors in a desired configuration;
and 61 denotes a metal conductor embedded in an insulating separator strip; 7 denotes an outer insulating jacket; and 9 denotes a low resistivity conductive material at the junctions of the heating strip and the conductors.

Referring now to Figures 1-4, a single heating strip 1 is wrapped helically around conductors 3 and 4 and separator strip 6. Electrical contact between the heating strip and the conductors is enhanced by means of low resistivity material 9 which forms a fillet between the strip and the conductor at the contact points. The 6~3 -l9- MP0821/A

separator strip may consist of polymeric insulating material (Figure 2), or comprise a metal conductor embedded in polymeric insulating material (Figure 3), or consist of a conductive polymer composition (Figure 4). Figures 5 and 6 are very similar to Figures l and 2 except that there are two heating strips l and 2. Figure 7 shows a heater which is suitable for use with a 3-phase power source and which comprises three conductors 3, 4 and 5 separated by a generally triangular insulating strip 6 and having a heating strip l wrapped around them. In each of Figures 1-7 there is a polymeric insulating jacket 7 which surrounds the heating strip, the conductors and the separator. Figure 8 is the same as Figure l except that it does not contain a separator strip, the insulating jacket 7 serving to maintain the conductors in the desired configuration. Figure 9 is similar to Figure l except that the heater strip is wrapped around the separator and the conductors are then brought into contact with the heating strip. Figures lO and ll show a heater in which heating strips l, 2, lA and 2A are spaced around an insulating separator strip 6 and conductors 3 and 4 are wrapped helically around the separator strip and the heating strips.

Figure 12 shows a heater in which a heating strip l is wrapped helically around four conductors 3, 4, 5 and 5A which are supported by a metal pipe 61 which is surrounded by insulating material 6. Figures 13 and 14 show a heater in which conductors 3 and 4 are wrapped helically around a core comprising an insulating strip 6 sandwiched between heating strips l and 2. Figures 15 and 16 show a heater which is the same as that shown in Figures 13 and 14 except that the conductors are wrapped lZ(~

in a Z-configuration so that they cross the heating strips 1 and 2 at right angles. Figures 17 and 18 show a heater in which a heating strip 1 is laid down in a sinusoidal path on top of conductors 3 and 4.

Figures 19, 20, 21 and 22 show cross-sections of different heating strips which can be used in the invention. Figure 19 shows a strip which is a simple melt-extrudate of a PTC conductive polymer. Figure 20 shows a strip which contains a melt-extruded core 12 of a 1û ZTC conductive polymer and a melt-extruded outer layer 11 of a PTC conductive polymer. Figure 21 shows a strip which contains an insulating core 13 and a melt-extruded outer layer 11 of a PTC conductive polymer. Figure 22 shows a multifilament glass yarn which has been coated, at least on its surface, with a conductive polymer composition, e.g. by passing the yarn through a water or solvent-based composition followed by drying.

EXAMPLES

The invention is illustrated in the following Examples, which are summarized in the Table below. In each Example, the ingredients and parts by weight thereof listed in the Table were dry-blended, melt-extruded through a twin screw extruder and chopped into pellets. The pellets were melt-extruded through a Brabender extruder fitted with a die of the diameter shown in the Table, and the extrudate was drawn down to the extent necessary to give a PTC
heating strip of the diameter shown. In Example 6, the conductive polymer was extruded around a glass fiber yarn which had a diameter of 0.042 cm, and which had Z6~

previously been coated with a graphite emulsion and dried.
The heating strip was then wrapped around a pair of nickel-coated copper conductors of the size shown. In Example 1, the conductors were first coated with a graphite emulsion and then dried. In Example 6, the conductors were first coated with a layer 0.034 cm thick of the same composition as was used for the PTC heating strip. The wrapping of the strip was at the pitch shown. In Examples 1-4 and 6, a single strip was wound. In Example 5, two equispaced strips were wound. In Example 1, the conductors were maintained 0.63 cm apart while they were being wrapped. In the other Examples, the strip was wrapped around the conductors and a separator strip. The dimen-sions and materials of the separator strip are shown in the Table, and it is to be noted that in Examples 3-6, the separator contained an aluminum strip of the dimensions shown, encapsulated with the polymeric separator materials.
The separator strips had concave ends into which the conductors fitted. In Examples 2-6, the junctions between the conductors and the heating strip were coated with graphite emulsion and then dried. Finally, a polymeric jacket, of the material and thickness shown in the Table;
was applied by melt-extrusion around the heater. In Examples 2-49 the first jacket layer was a mixture of PFA
polymer and 5~0 by weight of glass fibers; the second layer (not indicated in the Table) was a tin-coated copper braid (12 end, 34 AWG); the final layer was composed of ETFE.
In Example 6, the jacket was a mixture of FEP polymer and 10~o by weight of glass fibers. The various ingredients used in the Table and referred to above are further identified below. The ETFE polymer was an ethylene/
tetrafluoroethylene copolymer sold by du Pont under the ~LZ~)82613 ,~
trade name Tefzel 2010. The PFA polymer was a tetrafluoro-ethylene/perf ~ oroalkoxy copolymer sold by du Pont under ~` the trade name Teflon PFA. The FEP polymer was a tetra-fluoroethylene/hexafluoro~ropylene copolymer sold by du Pont~ under the trade name Teflon FEP 100. The zinc oxide was Kadox 515 available from Gulf and Western~ Continex N330 is a carbon black available from Cabot. Vulcan XC-72 is a carbon black. The graphite emulsion was Electrodag 502, available from Acheson Colloids.

8;~6~3 . TABLE

Example No. 1 2 3 4 5 6 PTC Conductive Polymer ETFE polymer 66~6 PFA polymer - 88.2 B7.0 88.5 88.2 FEP polymer - - - - - 88.00 Continex N330 13.0 Vulcan XC-72 - 11.8 13.0 11.5 ll,S 8.94 Zinc Oxide 20.0 ~ 3.00 Process Aid 0.4 - - - - 0.06 Die Diameter (cm) 0.10 0.18 0.13 0.18 0.18 0022 _ Strip Diameter (cm) 0.05 0.11 0.12 0.11 0.11 *
Pitch (cm) 1.27 0.32 0.32 0.32 1.27 0.63 ~ .
Conductors AWG size 18 6 14 14 16 22 diameter (mm) 0.91 4.67 1.85 1.85 1,47 0~74 separation (cm) 0.63 0.58 0.76 1.07 0.76 0.76 coated Yes No No No No Yes Separator Strip No Yes Yes Yes . Yes Yes width (cm) - 0.58 0.76 1.07 0.76 0.76 thickness (cm) - 0.51 0.19 0.19 0~19 0.14 PFA/glass (5~O) - Yes ETFE/glass - - Yes Yes Yes HFP - - - - Yes A1 width (cm) - - 0.57 0.86 0.57 0.57 thickness (cm) - 0.04 0.04 0.04 0.04 Jacket None Polyethylene (cm)0.05 - - - -PFA/glass (cm) - 0.06 0.06 0.06 ETFE (cm) - 0.09 0.09 0.09 FEP/glass tcm) - - - - 0.063

Claims (15)

The embodiments of the invention in which an exclusive pro-perty or privilege is claimed are defined as follows:-

1. An elongate electrical heater which comprises (1) first and second elongate, spaced-apart, conductors which can be connected to a source of electrical power, and (2) an elongate resistive heating strip which (i) comprises an elongate resistive heating com-ponent which is composed of a conductive polymer exhibiting PTC behavior, and (ii) is in electrical contact alternately with the first conductor and the second conductor at contact points which are longitudinally spaced apart along the length of the strip and along the length of each of the conductors.

2. A heater according to Claim 1 wherein the heating component has been produced by melt-extrusion of the conduc-tive polymer.

3. A heater according to Claim 1 wherein the conductive polymer component has a resistivity at 23°C of 100 to 5,000 ohm.cm.

4. A heater according to Claim 1, 2 or 3 wherein the heating strip is wrapped around the conductors.

5. A heater according to Claim 1, 2 or 3 wherein the heating strip is wrapped around the conductors and has a resistance at 23°C of at least 10 ohms per cm length and a cross-sectional area of at least 0.0001 cm2.

6. A heater according to Claim 1, 2 or 3 wherein the heating strip is wrapped around the conductors and has a resistance at 23°C of at least 100 ohms per cm length and a cross-sectional area of at least 0.001 cm2.

7. A heater according to Claim 1 wherein the heating strip consists essentially of a conductive polymer.

8. A heater according to Claim 1, 2 or 3 wherein the heating strip comprises an elongate element of an electri-cally insulating material which is surrounded by a conduc-tive polymer component.

9. A heater according to Claim 1, 2 or 3 wherein the heating strip is wrapped around the conductors, wherein the conductors are 0.5 to 1.5 cm apart and at least one heating strip is wrapped around the conductors at a pitch of 0.20 to 2.5 cm.

10. A heater according to Claim 1, 2 or 3 wherein the heating strip is wrapped around the conductors and which further comprises a separator strip which lies between the conductors and which comprises electrically insulating material so that, when the conductors are connected to a power source, all the current passing between the conductors passes through the heating strip.

11. A heater according to Claim 1, 2 or 3 which further comprises a second resistive heating strip which is composed of a conductive polymer composition and which is in electrical contact with the conductors.

12. A heater according to Claim 1, 2 or 3 wherein the heating strip comprises a first conductive polymer composition which exhibits PTC behavior with a switching temperature Ts and the heater further comprises a second resistive heating strip which is in electrical contact with the conductors and which comprises a second conductive polymer composition which exhibits PTC behavior with a switching temperature substantially different from Ts.

13. A heater according to Claim 1, 2 or 3 wherein the heating strip comprises a first conductive polymer composition which exhibits PTC behavior with a switching temperature Ts and the heater further comprises a second resistive heating strip which is in electrical contact with the conductors which is composed of a conductive polymer composition exhibiting ZTC behavior at temperatures below Ts, and which provides a current path between the conductors whose resistance (a) is higher than the resistance of the current path along the first heating strip when the heater is at 23°C and (b) is lower than the resistance of the current path along the first heating strip at an elevated temperature.

14. A heater according to Claim 1, 2 or 3 wherein the conductors are wrapped around the heating strip and an insu-lating strip.

15. A heater according to Claim 1, 2 or 3 wherein there is a coating of a ZTC conductive polymer composition over the contact points between the conductors and the heatina strip.