Thermal fabric

FIELD: production of fabrics which generate heat by means of power source and may be used for manufacture of clothing, seats, quilts, etc.

SUBSTANCE: thermal fabric comprises non-conductive thread, heating thread with positive temperature coefficient, and two current-conductive terminals. Heating thread comprises core, enclosure made from matrix including embedded current-conductive particles, and isolating sheath.

EFFECT: provision for creating fabric free of wires and possessing the function of self-regulating heating.

29 cl, 5 dwg

 

The present invention relates to the tissues, which generate heat by using source of electricity.

Known tissue, generating heat, which contain electrically conductive filaments that generate heat when applying for their electricity. However, electrically conductive filaments that are used to generate heat, are not self-regulating, and without the protection of the fabric may occur.

To ensure the function of self-regulation in the generation of heat in tissue was used heat-generating wire. Typically, self-regulating cables consist of two parallel conductors located between heat generating material. The wire generates heat when two conductors are powered on. To control the heat generation of the wire material, generating heat and located between the two conductors, has characteristics of increasing resistance with increasing temperature and decrease of the resistance with decreasing temperature. However, the wires embedded in the fabric, cause non-uniformity in the product, which bring inconvenience to the users.

Thus there is a need in thermoscani, which has the function of self-regulation heating without the use of wires.

According to the object of the present invention created elmadani, containing at least one electroconductive thread; at least one heating filament with a positive temperature coefficient, having a resistance of from 0.1 to 2500 Ohms per inch (from 0.04 to 985 Ohms per centimeter), and two electrically conductive conclusion, in which the heating filament contains a core and a shell made from a matrix which includes conductive particles and the matrix material has a higher coefficient of thermal expansion than the particles, and the insulating coating.

Preferably, the shell is made from a material with a positive temperature coefficient of resistance.

The core of the heating filament with a positive temperature coefficient may contain monovacancy core, multi-fiber core or a core staple fiber and staple fiber core is twisted staple fiber.

Preferably, the shell contains a separate electrical conductors enclosed in an expanding when heated matrix with low electrical conductivity, and the matrix has a greater coefficient of thermal expansion than the electrical conductors. The matrix may be crosslinked or to have a specific softening temperature at which the conductivity drops sharply when reaching selected the temperature.

In addition, terkadang may further comprise an insulating coating applied on top of thermoscani.

Preferably, the heating filament with a positive temperature coefficient has a round cross-section.

Most preferably, the heating filament with a positive temperature coefficient has an oval cross-section.

The heating filament with a positive temperature coefficient may have a flat cross-section.

Mainly, terkadang further comprises at least one electrically conductive conclusion connected with a heating filament with a positive temperature coefficient.

Alternatively, terkadang further comprises two electrically conductive output, and heating the filament with a positive temperature coefficient is electrically connected between these two pins.

Preferably, at least one heating filament with a positive temperature coefficient contains many heating threads with a positive temperature coefficient further comprises two electrically conductive conclusion, while heating the filament with a positive temperature coefficient connected in parallel between the two conductive pins.

In addition, preferably, terkadang is a textile fabric. Most PR is doctitle, to terkadang additionally contain at least one conductive conclusion connected with a heating filament with a positive temperature coefficient.

Preferably, terkadang further comprises two electrically conductive output, and heating the filament with a positive temperature coefficient is electrically connected between the two conductive pins.

Preferably, at least one heating filament with a positive temperature coefficient contains many heating threads with a positive temperature coefficient further comprises two electrically conductive conclusion, while heating the filament with a positive temperature coefficient connected in parallel between the two conductive pins.

Mainly, terkadang is a knitted fabric.

Preferably, the heating filament forms a loop of the knitted fabric.

Preferably, the heating filament is woven into the loops of the electroconductive threads.

Terkadang may further comprise at least one electrically conductive output connected to a thread with a positive temperature coefficient.

Preferably, the output contains conductive thread, terkadang contains knitted fabric, conductive thread arr is not a loop knitted fabric.

Most preferably, conductive conclusion was woven into the loop of the electroconductive threads.

Preferably, terkadang contains a knitted fabric, and the conclusion is woven into the loops of the electroconductive threads.

In addition, terkadang may further comprise two electrically conductive output, in this case the heating filament with a positive temperature coefficient is electrically connected between the two conductive pins.

Preferably, at least one heating filament with a positive temperature coefficient contains many heating threads with a positive temperature coefficient further comprises two electrically conductive conclusion, while heating the filament with a positive temperature coefficient connected in parallel between the two conductive pins.

Hereinafter the invention is described in more detail with reference to the accompanying drawings, on which:

Figure 1 is an enlarged cross-section of the heating filament for use in the present invention.

Figa and 2B - fabric illustrating the alternatives of the present invention.

Figa and 3B - knitted fabric, illustrating alternatives of the present invention.

According to the present invention terkadang or the material may be woven, is provided or any similar material, made at least partially of electrically conductive filaments to generate heat using the power source. The fabric may be flat, hairy or have a different configuration. The fabric contains a conductive filament (heater), conductivity and location are consistent with the source of electricity that will be used to generate heat. Heaters can take in the direction of the warp and weft. It is possible (but not necessary) to use a variety of conductive cores (conclusions), for example, in the form of filaments connected to the heater to supply them electricity. Not having conductive threads are usually included in the design for mechanical stability. In one embodiment, the fabric is made in the form of a continuous rolled strip, as well as traditional fabric, which is then cut into the necessary parts ("panel") for use in the finished product. Terkadang can be used as the substrate, stacked for ordinary cloth, or can be used as the outer fabric such as upholstery material.

In the present invention the heater is a thread with a positive temperature coefficient (PTC). Thread with PTC is a conductive filament, the resistance of which increases with temperature and decreases with decreasing temperature. Thread with PTC typically contains a material with a positive temperature coefficient, which has the property of increasing resistance with increasing temperature and decrease the resistance with decreasing temperature. In one embodiment, the thread with PTC is the thread with the electroconductive core or core having low conductivity, and a cover made of material having PTC. An example of such a yarn consisting of a core and a shell, suitable for use as a heater in the fabric of the present invention described in application for U.S. patent No. 09/667065 "Thread, the electrical resistance which varies with temperature", filed September 29, 2000 by DeAngelis and others, which is fully incorporated into the present description by reference.

An example of such a filament with a core/shell, which can be used as a heating filament in the present invention, also shown in figure 1, as the thread 10. As shown in figure 1, the thread 10 generally includes a core 11 and a shell 12 with a positive temperature coefficient of resistance. As shown in the drawing, the thread 10 may also include an insulator 13, located above the shell 12. As shown in the drawing, the filament 10 has a circular cross-section, but the thread 10 may have other shaped cross-section, suitable for forming tissue, such as oval, flat, etc.

The core 11 may generally be made of any material, with sufficient flexibility and strength to be used as a textile yarn. The core may be made of synthetic fibers such as polyester, nylon, acrylic, rayon, Kevlar, Nomex, etc. or may be formed from natural fibers, such as cotton, wool, silk, linen and other Core 11 may be formed from monofilament, multi-fiber or staple fiber. In addition, the core 11 may be flat, spinning or thread of any other type, used in the textile industry. In one embodiment, the core 11 is made as the electroconductive material.

The shell 12 with a positive thermal coefficient of resistance is a material which increases its electrical resistance with increasing temperature. In the embodiment of the present invention, is shown in figure 1, the shell 12 includes a separate electrical conductors 21, mixed matrix 22 having low thermal conductivity and expanding when heated.

Individual conductors 21 provide a conductive path through the shell 12. These individual conductors 21 is preferably in the form of particles, for example particles of electrically conductive materials, spheres, coated with electrically conductive material, electrically conductive flakes, conductive fibers and other Conductive particles in the fibre or flakes can be made of materials such as copper, graphite, gold, silver, carbon, or any other similar electrically conductive material. Spheres and microspheres in one embodiment, are spheres with a diameter of from about 10 to about 100 microns.

Matrix 22 has a higher coefficient of thermal expansion than the conductive particles 21. The matrix material 22 is selected so that it could expand with increasing temperature, thereby pushing various electrically conductive particles 21 from each other inside the matrix 22. Such extracting conductive particles 21 leads to increase in the electrical resistance of the shell 12. The matrix 22 is flexible to the extent that this is necessary to embed in the thread. In one embodiment, the matrix 22 is ethylenediurea (EEA), or a combination of AAA with polyethylene. Other materials that can meet the requirements for materials used in the matrix 22 include, without limitation, polyethylene, polyolefins, halogenated derivatives of polyethylene, thermoplastic or thermosetting materials.

The shell 12 may be applied to the core 11 by means of extrusion, coating or otherwise applying a layer of material on the core 11. Selection of a particular type of individual conductors 21 (i.e. flakes, fibers, spheres, etc.) may determine different characteristics and the dependence of resistance on temperature, and also affect the mechanical properties of the shell 12. The matrix 22 may be formed so as to impede or prevent softening or melting at operating temperatures. It was determined that the useful resistance filament 10 can range from about 0.1 Ohm per inch to approximately 2500 Ohms per inch (from 0.04 to 985 Ohms per centimeter, depending on the desired application type.

In one embodiment of the present invention, the matrix 22 may melt at a certain temperature to create inline "fuse"that will break the conductivity of the matrix 22 upon reaching the selected temperature.

The insulator 13 is an electroconductive material, which by its flexibility is consistent with the thread. In one embodiment, its coefficient of expansion close to the coefficient matrix 22. The insulator 13 may be thermoplastic, thermosetting plastic or thermoplastic, which becomes thermosetting plastic after appropriate processing, such as polyethylene. Materials suitable for use in the insulator 13 are polyethylene, polyvinyl chloride or the like. The insulator 13 may be applied to the shell 12 by extrusion, coating, wrapping or wrapping and heating of the material of the insulator 13.

The voltage applied the filament 10, causes the current to flow on the shell 12. As the growth temperature of the filament 10, the resistance of the shell 12 is growing. It is believed that the increase of the resistance of the filament 10 is achieved by expanding the matrix 22, resulting in extended conductive particles 21 placed inside the matrix 22, thereby destroying micropore passing along the length of the filament 10, and increasing the total resistance of the shell 12. This specific dependence of conductivity on temperature is not suitable for every application. For example, the conductivity can grow slowly up to a certain point, and then rise sharply at a given temperature cutoff.

To facilitate electrical connection threads with a positive temperature coefficient can use heat and pressure to soften the material with a positive temperature coefficient and to obtain a more integral connection. In addition, electrically conductive yarn in the fabric can be pre-coated with highly conductive material to improve the electrical connections in the finished fabric.

The heating filament can be located at a distance of 1-2 inches (to 25.4-50.8 mm) from each other to provide uniform heating, but the distance between them may be more or less that does not change the basic principles of the present invention. Use the thread with a positive temperature coefficient for heating allows you to embed a system of temperature control directly in the fabric, because the heating from the filament with a positive temperature coefficient decreases with increasing temperature this thread. Therefore, as the growth temperature thermoscani grows and the filament resistance with a positive temperature coefficient, thereby reducing the amount of heat generated by this cloth. On the contrary, if the temperature of thermoscani falls, the filament resistance with a positive temperature coefficient decreases and terkadang generates more heat.

Conclusions usually (but not always) have higher electrical conductivity and are less than the heaters. In one embodiment, the conclusions are threads from a material with high electrical conductivity. In another embodiment, the findings may be strands of conductive wire, for example, of Nickel, having approximately the same cross-sectional area with the threads of the fabric.

To improve the mechanical properties of the structure may be any electroconductive thread. For example, a fabric with a heating filament in a duck may have additional electroconductive weft threads, which increases the mechanical stability for high temperature applications can be used with glass or Armidale threads etc.

Terkadang may be covered with insulating material to protect the fabric during washing or use. Such a coating can be any of the insulating polymer, which may be applied to the heaters in any convenient way. The coating thickness may be different, but in one embodiment it is from about 5 mils to about 13 mils (to 0.127-0,3302 mm). Can be used acrylics because they have high insulating properties, are flexible and not sticky. Flexibility helps to ensure that the panel retains the properties of the tissue. The low viscosity allows the fabric to retain after coating some breathability. The open design of the present invention allows the application of the coating on the fabric without sudden loss of permeability. Breathability is important for comfort, for example, in the manufacture of clothing, seats or blankets. The coating also improves the mechanical stability, which is especially important to ensure the reliability of electrical connections in the tissue. It can also be used to make fabric properties non, vodootlivnye or other properties, typical fabrics coated.

On figa and 2B shows a textile fabric 210 and 220, respectively, illustrating variants of the present invention. As shown in figa, fabric 210 contains a lot of electroconductive yarns 13, woven into a fabric with mixed continuous heating filament 11. Heat is generated tissue 210 when a voltage is applied to daconta heating filament 11. As shown in figv, fabric 220 contains many heating threads 11, the connecting threads 12 and electroconductive yarns 13, woven into the fabric. The heating filament 11 in the tissue 220 are connected in parallel between the connecting threads 12. Heat is generated when voltage is applied on the connecting threads 12.

On figa and 3B shows a knitted fabric 310 and 320, respectively, illustrating variants of the present invention. As shown in figa, canvas 310 contains electroconductive filament 13, woven into the fabric, and heating the filament 11, laid in the same canvas. Heat is generated in the tissue 310 when a voltage is applied to the two ends of the heating filament. As shown in figv, canvas 320 contains electroconductive filament 13, woven into the fabric, and heating the filament 11, and the connecting thread 12 laid in the same canvas. The heating filament 11 are connected in parallel between the connecting threads 12. Heat is generated in the tissue 320 when voltage is applied on the connecting threads 12. Although in the tissues 310 and 320 shown a heating filament 11 and the connecting thread woven into the knitted fabric of the electroconductive yarns 13, the present invention provides for the heating of the filaments 11 and/or the connecting threads 12 for forming the knitted loops of the fabric 310 or 320.

Surface goth is howling tissue can get away. Appropriate finishing techniques depend on the type of thread. Special demand can use fleecy fabric with conductive yarns in the warp.

Advantages of tissue heater compared to a traditional wired design are flexibility, breathability, fast heating, uniform heat distribution and the details of the profile (due to the absence of wires). In some cases, the fabric may simplify the manufacture of the final product, because the fabric can be laminated or sew in the final design or use in roll form. The heating filament of a material with a positive temperature coefficient are self-regulating and are generally more preferred than traditional heaters. Due to the presence of material with a positive temperature coefficient fabric gets a built-in control mechanism or eliminates the need for temperature feedback or external control circuits temperature.

1. Terkadang containing at least one electroconductive thread, at least one heating filament with a positive temperature coefficient, having a resistance of from 0.1 to 2500 Ohms per inch (from 0.04 to 985 Ohms per centimeter), and two electrically conductive conclusion, in which the heating filament with whom holds the core and the shell, made from a matrix which includes conductive particles and the matrix material has a higher coefficient of thermal expansion than the particles, and the insulating coating.

2. Terkadang according to claim 1, in which the shell is made from a material with a positive temperature coefficient of resistance.

3. Terkadang according to claim 2, in which the core of the heating filament with a positive temperature coefficient contains monovacancy core.

4. Terkadang according to claim 2, in which the core of the heating filament with a positive temperature coefficient contains multi-fiber core.

5. Terkadang according to claim 2, in which the core of the heating filament with a positive temperature coefficient contains the core of staple fibers.

6. Terkadang according to claim 5, in which the staple fiber core is twisted staple fiber.

7. Terkadang according to claim 2, in which the shell contains a separate electrical conductors enclosed in an expanding when heated matrix with low electrical conductivity, and the matrix has a greater coefficient of thermal expansion than the electrical conductors.

8. Terkadang according to claim 7, in which the matrix is crosslinked.

9. Terkadang according to claim 7, in which the matrix has a specific softening temperature at which the power shall vodnosti sharply decreases when reaching the selected temperature.

10. Terkadang according to claim 1, additionally containing an insulating coating applied on top of thermoscani.

11. Terkadang according to claim 1, in which the heating filament with a positive temperature coefficient has a round cross-section.

12. Terkadang according to claim 1, in which the heating filament with a positive temperature coefficient has an oval cross-section.

13. Terkadang according to claim 1, in which the heating filament with a positive temperature coefficient has a flat cross-section.

14. Terkadang according to claim 1, additionally containing at least one electrically conductive conclusion connected with a heating filament with a positive temperature coefficient.

15. Terkadang according to claim 1, additionally containing two electrically conductive output, in this case the heating filament with a positive temperature coefficient is electrically connected between these two pins.

16. Terkadang according to claim 1, in which at least one heating filament with a positive temperature coefficient contains many heating threads with a positive temperature coefficient further comprises two electrically conductive conclusion, while heating the filament with a positive temperature coefficient connected in parallel between the two conductive pins.

17. Terkadang according to claim 1, in which terkadang one is camping textile cloth.

18. Terkadang on 17, further containing at least one electrically conductive conclusion connected with a heating filament with a positive temperature coefficient.

19. Terkadang on 17, further comprising two conductive output, in this case the heating filament with a positive temperature coefficient is electrically connected between the two conductive pins.

20. Terkadang on 17, in which at least one heating filament with a positive temperature coefficient contains many heating threads with a positive temperature coefficient further comprises two electrically conductive conclusion, while heating the filament with a positive temperature coefficient connected in parallel between the two conductive pins.

21. Terkadang according to claim 1, in which terkadang is a knitted fabric.

22. Terkadang on item 21, in which the heating filament forms a loop of the knitted fabric.

23. Terkadang on item 21, in which the heating filament is woven into the loops of the electroconductive threads.

24. Terkadang on item 21, further containing at least one electrically conductive output connected to a thread with a positive temperature coefficient.

25. Terkadang on item 21, in which the output contains conductive thread, those whom modani contains a knitted fabric, and electrically conductive filament forms a loop of the knitted fabric.

26. Terkadang on item 21, in which the conductive conclusion woven into loops of electroconductive threads.

27. Terkadang on item 21, in which terkadang contains knitted fabric, this conclusion is woven into the loops of the electroconductive threads.

28. Terkadang on item 21, further comprising two conductive output, in this case the heating filament with a positive temperature coefficient is electrically connected between the two conductive pins.

29. Terkadang on item 21, in which at least one heating filament with a positive temperature coefficient contains many heating threads with a positive temperature coefficient further comprises two electrically conductive conclusion, while heating the filament with a positive temperature coefficient connected in parallel between the two conductive pins.



 

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