CN101542039B - 柔性印刷导电织物及其制造方法 - Google Patents

柔性印刷导电织物及其制造方法 Download PDF

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CN101542039B
CN101542039B CN2007800416462A CN200780041646A CN101542039B CN 101542039 B CN101542039 B CN 101542039B CN 2007800416462 A CN2007800416462 A CN 2007800416462A CN 200780041646 A CN200780041646 A CN 200780041646A CN 101542039 B CN101542039 B CN 101542039B
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conductive layer
conductive
conductive fabric
fabric
basic unit
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CN101542039A (zh
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朴省美
曹光洙
郑京姬
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Kolon Glotech Inc
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Kolon Glotech Inc
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Abstract

本发明提供了一种导电织物。该导电织物包括由合成的、再生的或天然纤维构成的基层；形成于基层之上以能够以预设计的电图案自由形成的导电层；和在导电层之上形成以防止导电层损坏的绝缘层。

Description

柔性印刷导电织物及其制造方法
技术领域
本发明涉及柔性印刷导电织物(conductive fabric，下文中被称作“导电织物”)及该导电织物的制造方法，更具体而言，涉及可以以自由或任意方式形成导电电路图案的导电织物及该导电织物的制造方法。
背景技术
智能服装是一种采用新型纤维技术新型产品，该技术可将信号传输至嵌入纺织式样产品中的多种数字器件，以便在任何时间及任何地点都可利用该数字器件的数字化特性。也就是说，智能服装是向纤维材料或衣料提供想要的数字化特性同时保持该纤维材料或衣料的性质而制造的新型衣服。因此，智能服装需要传输数字信号同时产生与一般纺织物相同的触感和物理特性。总而言之，智能服装是对结合了具有未在衣服和纺织物中发现的数字化特性的纤维或布类的高性能材料特性(例如，对外部刺激的感应和对刺激的自身应答self-response to the stimuli)的新型衣服概念的统称。
从20世纪九十年代中期开始产生了用于军事应用的智能服装并且其目前被发展到多个领域，尤其是衣服及医药应用。特别地，基于电子印刷技术的智能材料可以用于制造军事纺织产品用于可穿戴式计算机。通过将具有衣料特征及电特性的导电纤维或纺织物连接至多种电子组件和部件这样的方式(互联方法)，将电子印刷技术应用于智能材料可以设计基于纺织物的电子电路。因此，电子印刷技术在开发智能服装上很有价值。例如，电子印刷技术在军服上的应用提供了降低军服重量和体积的可能性，从而使整合想要的功能的军服的开发得以可能，例如损伤康复和通讯。士兵在全副武装进行当代高科技战争时还必须携带45kg的装备。这种情况下，急需开发一种与单兵区域网络(BAN)的多种因素相结合的相关适宜技术以生产智能服装。
为了满足这一需求，已经提出多种建议。例如，将绝缘的电线、电导金属纱线或绝缘纱用于机织物。该纺织物导电性由金属纱线或纱的数量及尺寸决定。
与将绝缘的电线附接到最终的服装相关的问题是必须包括另一涂饰处理以附接/绝缘该绝缘的电线。额外的涂饰处理需要生产成本的增加。此外，连续穿着衣服造成绝缘的电线断线，这使得很难展示该衣服的内在功能。
PCT国际公开No.WO2004/107831提出包括一种或多种导电纤维及与所述一种或多种导电纤维协作的一种或多种非导电纤维的纤维构造以形成至少一种织物界面，其中所述非导电纤维向该纤维构造提供弹性以便所述至少一种织物界面选择性地展现和/或可以以符合纤维构造伸长来使用。
此外，PCT国际公开No.WO2003/095729提出了其中具有电子功能机织物的多层机织制品，包括：经纱和纬纱，其在具有其中限定至少一个腔的多层的多层机织物中交织；至少一个电导纱线，其置于经纱和/或纬纱中并且其一部分在限定至少一个腔的多层之一中；和电路载体，其置于腔中并且至少一个暴露的电连接与所述至少一个电导纱线电连。
同时，用作智能服装的基本材料的织物需要下述动态耐磨性特征。穿戴者和装置的物理需要包括装置的放置、装置的形成语言、人运动、人对亲密空间的感知、尺寸变化和装置的附接。
此外，就穿戴者和环境氛围间的关系而言，考虑装置的污染、装置的重量、可及性、感应相互作用、热舒适性、美感、长期效果等(Gemperle，F.；Kasabach，C.；Stivoric，J.；Bauer，M.；Martin，R.；(1998)“Design for Wearability，”Digest ofPapers，2nd International Symposium of Wearable Computer，IEEE ComputerSociety)。
这一连接中，很难设计所提出的用于智能服装的电导纺织物以便对应于电子装置的放置和形式。换言之，就穿戴者和装置的物理需要而言，没有替代可以提供。此外，从保持纤维内在性质的观点看，所提出的织物在纤维体积、冲洗特征等方面受到很大限制。
发明内容
技术问题
为了努力解决上述问题进行本发明，并且本发明的一个目的是提供一种可以自由形成电路而对动态耐磨性则没有任何限制的导电织物，及该导电织物的制造方法。
本发明的另一目的是提供一种可以自由设计电路而不管电子装置的形式或放置的导电织物，以及该导电织物的制造方法。
本发明的另一目的是提供一种不因电路断线而有任何缺陷或电路故障的导电织物，以及该导电织物的制造方法。
本发明的另一目的是提供一种展现令人满意的电特性而不使可用作衣服材料的纺织物的固有物性变坏的导电织物，以及该导电织物的制造方法。
本发明的另一目的是提供一种其电路的一个或多个弯曲部分被设计改变以允许电流平滑地流动的导电织物，以及该导电织物的制造方法。
本发明的再一目的是提供一种可冲洗的导电织物，以及该导电织物的制造方法。
技术方案
根据用于实现上述目的的本发明的一个方面，提供一种导电织物，包括由合成的、再生的或天然纤维构成的基层；形成于基层之上以能够以预设计的电图案自由形成的导电层；和形成于导电层之上以防止该导电层损坏的绝缘层。
该导电织物可还包括底层，该底层形成于基层和导电层之间以使基层表面均匀。
该底层可由选自由聚氨基甲酸酯、丙烯酸和硅树脂组成的组中至少一种树脂形成。
该底层可由带有拒水层的多层结构所形成。
该导电层可由选自由导电聚合物、碳、诸如银的金属材料及它们与粘结剂的混合物组成的组中至少一种材料所形成。
该导电聚合物可选自由聚苯胺、聚吡咯、聚噻吩及其混合物组成的组。
该导电材料和粘结剂可能以重量比90∶10至80∶20混合以形成导电层。
该粘结剂可选自由聚氨基甲酸酯树脂、丙烯酸树脂、硅树脂、三聚氰胺树脂、环氧树脂及其混合物组成的组。
该粘结剂可能是水分散型聚氨基甲酸酯树脂。
该导电层可具有厚度为2μm至500μm。
该导电层可具有厚度为10μm至20μm。
该导电层可具有宽度为10mm至20mm。
该绝缘层可通过在导电层上涂覆、印刷或层压至少一种树脂而形成，该树脂选自由聚氨基甲酸酯、丙烯酸、硅、聚酯、聚氯乙烯(PVC)和聚四氟乙烯(PTFE)组成的组。
该导电层可具有一个或多个电路弯曲部分的增大部分，其宽度大于该电路的线性部分。
该增大部分可具有圆形或卵形。
本发明的导电织物在冲洗前后可具有电阻差为0.5Ω至4Ω。
根据本发明的另一方面，提供一种制造导电织物的方法，该方法包括下述步骤：在由合成的、再生的或天然纤维构成的基层上形成电子可以经其流动的导电层，和在该导电层上形成绝缘层以防止该导电层损坏。
该方法可进一步包括在基层上形成底层的步骤以保持导电层的厚度为恒定水平。
该底层可由带有拒水层的多层结构所形成。
本发明的方法可进一步包括使用压辊在形成导电层之前加压于基层的步骤(压延步骤)以使基层的表面平滑，产生基层的孔和提高导电织物的抗挠性。
可选择地，该方法可进一步包括在压延步骤后对基层进行透气性防水处理或防水处理以形成导电层的孔并且增强导电织物的绝缘特性，耐冲洗性和抗挠性
该底层可通过刀辊、过辊(over roll)涂覆、浮刀涂覆、或辊式刮刀涂覆所形成。
该底层可由选自由聚氨基甲酸酯、丙烯酸和硅树脂组成的组中至少一种树脂所形成。
导电层可由选自由导电聚合物、碳、诸如银的金属材料、及它们与粘结剂的混合物组成的组中至少一种材料所形成。
该导电聚合物可选自由聚苯胺、聚吡咯、聚噻吩及其混合物组成的组。
该金属材料和粘结剂可以重量比90∶10至80∶20混合以形成导电层。
该粘结剂可选自由聚氨基甲酸酯树脂、丙烯酸树脂、硅树脂、三聚氰胺树脂、环氧树脂及其混合物组成的组。
该粘结剂可能是水分散型聚氨基甲酸酯树脂。
该导电层可具有厚度为2μm至500μm。
该导电层可具有厚度为10μm至20μm。
该导电层可具有宽度为10mm至20mm。
该绝缘层可通过在导电层上涂覆、印刷或层压至少一种树脂而形成，所述树脂选自由聚氨基甲酸酯、丙烯酸、硅、聚酯、聚氯乙烯(PVC)和聚四氟乙烯(PTFE)树脂组成的组。
该绝缘层可通过干燥涂覆、热熔网点(dot)层压或凹版层压所形成。
该导电层可具有一个或多个电路弯曲部分的增大部分，其宽度大于该电路的线性部分。
该增大部分具有圆形或卵形。
本发明的导电织物在冲洗前后具有电阻差为0.5Ω至4Ω。
有益效果
根据本发明的导电织物及方法，可以在导电层上自由地形成图案以实现导电织物的电导性同时保证该导电织物的多种动态耐磨性功能。
此外，根据本发明的导电织物及方法，由于作为基层材料的纤维的弹性和柔性，可以不顾弯曲或折叠而设计电路以基本上防止电路损坏，例如断线。
此外，根据本发明的导电织物及方法，可以以连续工艺制造该导电织物。
另外，本发明的导电织物及方法表现出电导性(即电流流动)同时保有织物(即衣料)的内在功能(例如，涂覆性、舒适性、透气防水性和拉伸强度)。
有益地，本发明的导电织物是可冲洗的并且具有高耐机洗性。
此外，根据本发明的导电织物及方法，由于存在底层以允许恒定的电流从其中流过，因此可以保持导电层的均一。
此外，根据本发明的导电织物包括导电层和由与该导电层兼容的材料所形成的绝缘层以实现高抗挠性。
附图说明
图1是根据本发明的优选实施方式的导电织物的横截面视图。
图2和3是流程图，示出根据本发明的实施方式的制造导电织物的方法。
图4和5是根据本发明的实施方式具有均一的弯曲部分的导电层图案和具有导电织物的宽弯曲部分的导电层图案的解释性视图。
图6-9是示出实施例1中经过一次冲洗后制造的导电织物的导电层、实施例2中经过1次冲洗后制造的导电织物的导电层、实施例7中经过4次冲洗后制造的导电织物的导电层和实施例8中经过4次冲洗后制造的导电织物的导电层的表面的照片。
图10是示出实施例1-4所制造的导电织物在多次冲洗前后的电阻变化的图表。
图11是示出实施例所制造的一些导电织物在多次冲洗前后的电阻变化的图表。
图12是示出在实施例所制造的一些导电织物在冲洗多次前后以及具有变化含量的粘结剂的电阻变化的图表。
图13-16是实施例7所制造的织物的分开部分A、B、C和D的应力应变曲线。
图17是示出实施例7所制造的织物的分开部分A、B和C在拉伸形变时的电阻变化的图表。
附图中基本部件的简单解释
10：导电织物，100：基层，
200：底层，300：导电层，
400：绝缘层。
具体实施方式
下文中将参考附图具体描述本发明的优选实施方式。应该指出只要可能，相同的数字将在整个附图和说明书中被用于表示相同或相似的部件。在描述本发明中，为了避免本发明的实质主题不清，省略对相关的已知功能或构造的具体描述。
如本文给出了确切或绝对数值以帮助理解本发明的公开文本，所使用术语“约”、“基本上”等意图允许在数学准确性中留有一些余地以解释行业中可接受的误差，并防止任何不负责任的违反者不正当地利用。
如本文所应用，术语“织物”意图包括机织制品或针织制品、非-机织物、纤维网等。
图1是根据本发明的优选实施方式的导电织物10的横截视图。
导电织物10包括基层100、底层200、导电层300和绝缘层400。可选择地，可以省略底层200。
任何类型的机织物或针织物、非-机织物、纤维网等可用于形成基层100。对基层的材料和形成方法没有特别的限制。例如，基层100可由合成纤维(例如，聚酯、聚胺或聚氨基甲酸酯)、纤维素再生的纤维(例如，粘胶或乙酸酯)或天然纤维(例如，棉或羊毛)所构成。
基层100由于纤维丝之间的间隙而具有非常不均一的微观表面和极其多的细孔。形成于基层100上的底层200使得基层100的表面均一并允许导电层形成为均一厚度。底层200防止导电层的组成材料渗透到基层100。可选择地，可在基层100上形成底层200。因此，应理解的是根据导电织物的特征可以包括该底层200。
底层200可由选自聚氨基酸酸酯、丙烯酸和硅树脂组成的组中的至少一种树脂所形成。
底层可能以单层结构或以带有拒水层的多层结构(未示出)形成。该拒水层可以由常规拒水处理方法所形成。合适的拒水层材料的非限制性实例包括氟和硅。可在导电层织物之上或之下形成拒水层以防止组成该导电层的树脂渗透到基层100。
电可以流经在底层200上形成的导电层300。导电层300的形状可以被预先设计并将在后面详细描述它。导电层300可由选自由导电聚合物、碳、诸如银的金属材料及它们与粘结剂的混合物组成的组中至少一种材料所形成。例如，导电层300由电导填料在载体中的分散所形成，其被印刷以形成电导固化膜。该导电层300的典型应用是LCD电极印刷、触摸屏印刷、用于电路板的导电图案印刷、薄膜开关板的接触印刷和图案印刷以及电磁屏蔽。适合用于本发明的导电填料的非限制性实例包括导电材料，例如银、铂、钯、铜、和镍。优选银。该导电聚合物可选自由聚苯胺、聚吡咯、聚噻吩及其混合组成的组。
导电层300优选具有的厚度为2μm至500μm。当导电层的厚度低于该范围，则很难保证导电层的厚度均一性。同时，当导电层的厚度高于该范围，则会造成电阻增加，导致功耗的增加。导电层更优选具有的厚度为10μm至20μm。导电层优选具有的宽度10mm至20mm。尽管导电层的宽度增加导致电阻减小和电流稳定，但导电层的宽度过度增加造成生产成本增加以及涂覆性差的问题。优选本发明的导电织物在冲洗之前和之后具有电阻差为0.5Ω至4Ω。实际上难以获得低于该范围的电阻差，而高于该范围的电阻差阻碍稳定的电流。
粘结剂可选自由聚氨基甲酸酯树脂、丙烯酸树脂、硅树脂、三聚氰胺树脂、环氧树脂及其混合物组成的组。优选地，该粘结剂是水分散型聚氨基甲酸酯树脂。
绝缘层400可通过将选自由聚氨基甲酸酯、丙烯酸、硅、聚酯、聚氯乙烯(PVC)和聚四氟乙烯(PTFE)树脂组成的组中至少一种树脂涂覆、印刷或层压于导电层300上而形成。绝缘层400执行防止导电层受损(例如裂纹)、赋予织物柔性和使织物透气防水或防水的功能。
下面参考图2和3将提供根据本发明优选的实施方式制造导电织物方法的解释。图2和3是说明该方法的流程图。
将用作基层100的材料的机织物或针织物引入两压辊之间以补偿纺织物表面的不规则性(压延)。进行压延以使基层100的表面平滑、产生基层100的孔和增强导电织物的抗挠性。该压延步骤可选择地依赖于基层100的织物特征。
底层200形成于基层上，该底层可选择地经历压延以实现对基层上的表面孔的更主动控制以及实现待形成于该底层上的导电层300的均一厚度。底层200可通过刀辊、过辊(over roll)涂覆、浮刀涂覆、或辊式刮刀涂覆、层压、印刷或凹版涂覆所形成。底层的形成是可选择的。
底层可由带有拒水层的多层结构所形成。该拒水层可以在压延步骤前或在该步骤后形成。图2和3的流程图分别说明在压延步骤前形成拒水层和在压延步骤后形成拒水层和/或底层，但本发明的方法不局限于此。
在底层200或基层之上形成导电层300。该导电层300被预先设计。导电层300可以通过多种技术而形成，例如涂覆、印刷和转印印刷。在本发明的具体实施方式中，通过印刷形成导电层300。这种情况下，可以根据预设计的图案在导电织物中设计电路而不考虑电子器件的放置。鉴于前述内容，本发明的导电织物可以被称为“柔性印刷织物电路板(FPFCB)”。
优选保持导电层300的厚度和宽度分别为2-500μm和10-20mm。优选保持导电织物在冲洗前后的电阻差为0.5Ω-4Ω。导电层可由按重量计1-30％的碳和按重量计1-70％的银构成。可以用于形成导电层的粘结剂选自由聚氨基甲酸酯树脂、丙烯酸树脂、硅树脂、三聚氰胺树脂、环氧树脂及其混合物组成的组，该粘结剂与底层200兼容。
图4和5示例性地示出根据本发明的实施方式导电织物的导电层。具体地，图4示出具有均一弯曲部分330的电路图案和图5示出具有弯曲部分330的增大部分350的电路图案，该弯曲部分的宽度大于电路图案的线性部分310。该增大部分350可具有任何形状。例如，该增大部分350具有圆形或卵形。
弯曲部分比线性部分宽的原因可以由下述方程所证明：
W＝I2R
R＝ρL/S(W：功率，R：电阻，ρ：比电阻，L：导线长度，和S：横截面积)。
随着横截面的增大，电阻减小而电流增大。因此，相比于线性部分310，更大量的电流流过该更宽的增大部分350。
弯曲部分330在预定角(例如直角)处造成电流的突然改变(即电涌(surge))以产生热。
电涌指在短时间内突然增大而在沿电线或电路流动期间逐渐减小的电流、电压或电功率的瞬态波形。电涌主要影响电闪时的断电，电话断线和感应半导体的损坏。因为突然过压，尤其是电源线的强电涌或长电涌可能造成介电击穿或电器件失调，将电涌保护器或抑制器安装到供电终端和计算机终端之间以抑制电流改变或使电流改变最小。
因此，尽管电流量增加，但通过改变弯曲部分330的面积来减小电阻以使电涌的发生最小并允许电子平滑地流经导电层。
可以在导电层300上形成绝缘层400。该绝缘层400可通过将溶剂型聚氨基甲酸酯树脂、水分散型聚氨基甲酸酯树脂、油溶性丙烯酸树脂、水溶性丙烯酸树脂、硅树脂、聚酯树脂或聚四氟乙烯(PTFE)树脂直接涂覆、印刷或层压于导电层300上而形成。优选使用干式涂覆、热熔网点层压或凹版层压以形成绝缘层。
用于绝缘层的涂层组成造成电阻变化，从而影响绝缘层的耐久性。
可以在导电织物的一个表面或两个表面上形成绝缘层。考虑到导电织物经历若干次冲洗的事实，选择适合长期绝缘(即优异的水洗牢度)的涂层组成是一重要因素。
压延步骤后，基层100可以选择性地进行透气性防水处理或防水处理。透气性防水处理或防水处理后形成的孔用于产生基层的孔并且用于实现导电织物增强的绝缘特性，耐冲洗性和抗挠性。用于透气性防水处理的材料优选与导电材料兼容的树脂(透气性防水处理/防水处理步骤)。
因此，根据本发明的方法，避免了在设计导电织物时预先形成电子流经的区域的需要，而可以在已经制造的织物或衣料上直接形成导电区域，并且尽管存在导电区域但对于导电织物的耐磨性不施加限制以保证导电织物的动态耐磨性。
发明的实施方式
实施例
实施例1
将作为基层的聚酯平纹织物进行压延和氟类拒水处理，并使用溶剂型聚氨基甲酸酯树脂在其上形成底层。通过丝网印刷将银浆施用到该底层以形成具有宽度为10mm和厚度为10μm的导电层，然后使用液体硅橡胶在导电层上形成绝缘层，从而完成导电织物的制造。
实施例2
按照与实施例1相同的方式制造导电织物，除了对基层只进行氟类拒水处理。
实施例3
按照与实施例1相同的方式制造导电织物，除了进行硅类拒水处理并使用硅和丙烯酸树脂的混合物形成底层。
实施例4
按照与实施例1相同的方式制造导电织物，除了对基层只进行硅类拒水处理。
实施例5
按照与实施例1相同的方式制造导电织物，除了使用重量比为90∶10的银浆和丙烯酸粘结剂的混合物形成导电层。
实施例6
按照与实施例2相同的方式制造导电织物，除了使用重量比为90∶10的银浆和丙烯酸粘结剂的混合物形成导电层。
实施例7
按照与实施例1相同的方式制造导电织物，除了使用重量比为90∶10的银浆和水分散型聚氨基甲酸酯粘结剂的混合物形成导电层。
实施例8
按照与实施例2相同的方式制造导电织物，除了使用重量比为90∶10的银浆和水分散型聚氨基甲酸酯粘结剂的混合物形成导电层。
实施例9
按照与实施例1相同的方式制造导电织物，除了使用重量比为90∶10的银浆和硅粘结剂的混合物形成导电层。
实施例10
按照与实施例2相同的方式制造导电织物，除了使用重量比为90∶10的银浆和硅粘结剂的混合物形成导电层。
实施例11
按照与实施例7相同的方式制造导电织物，除了使用重量比为95∶5的银浆和粘结剂形成导电层。
实施例12
按照与实施例7相同的方式制造导电织物，除了使用重量比为85∶15的银浆和粘结剂形成导电层。
实施例13
按照与实施例7相同的方式制造导电织物，除了使用重量比为80∶20的银浆和粘结剂形成导电层。
实施例14
按照与实施例8相同的方式制造导电织物，除了使用重量比为95∶5的银浆和粘结剂形成导电层。
实施例15
按照与实施例8相同的方式制造导电织物，除了使用重量比为85∶15的银浆和粘结剂形成导电层。
实施例16
按照与实施例8相同的方式制造导电织物，除了使用重量比为80∶20的银浆和粘结剂形成导电层。
实施例17
按照与实施例7相同的方式制造导电织物，除了通过丝网印刷形成导电层以具有宽度为20mm。
实施例18
按照与实施例7相同的方式制造导电织物，除了通过丝网印刷形成导电层以具有厚度为10μm。
比较例1
按照与实施例7相同的方式制造导电织物，除了不形成导电层。
试验结果
1、耐冲洗性
检测方法(KS K ISO 6330)
冲洗后测量分别由实施例和比较例制造的导电织物的电阻变化以检查在哪种条件下保证导电织物的耐冲洗性。具体地，在没有任何清洁剂下于卧式滚筒型洗衣机(WD-CR 1010，LG Electronics，Inc.)以适于羊毛的洗涤条件冲洗该导电织物(57min)并且在高温干燥1小时以测量导电织物的电阻和电阻变化。
表1
Figure G2007800416462D00121
Figure G2007800416462D00131
评价
如从表1可见，实施例7和8的样品的电阻增额相对较低，而实施例1和2的样品的电阻增额相对较高，因为在导电层的表面形成裂纹以至即使仅冲洗1次后也阻碍电流(图6和7)。即使冲洗4次后在实施例7和8的样品的导电层表面也没有发现损坏(图8和9)。相信粘结剂作用于提高基层和银浆之间的粘附，并且特别地，由于与银浆混合的聚氨基甲酸酯的内在特征(弹性)，水分散型粘结剂减小由冲洗造成的摩擦和物理形变以减小裂纹的出现，从而降低电阻增额。
2、对粘结剂含量依赖性的评价
检测方法(KS K ISO 6330)
冲洗后，测量具有变化的粘结剂含量(0-20wt％)的导电织物的电阻阻值和变化。结果如表2所示。
表2
Figure G2007800416462D00132
表2示出由于加入水分散型聚氨基甲酸酯粘结剂，电阻增额显著降低，但初始电阻值与粘结剂含量成比例增加。当粘结剂含量为5wt％时，耐冲洗性差，而当粘结剂含量为20wt％时，尽管耐冲洗性提高，但初始电阻值增加。相信当导电层在冲洗前后的电阻差在0.5Ω至4Ω的范围内时，将实现令人满意的导电性。
3、导电层放热温度的测量
当电阻升高超过预定水平时，由于施用电压时的负载而阻碍电流。因此，在各自实施例中制造的导电织物的导电层(尤其是供电连接器和图案)中可产生热。通过改变电极的厚度和宽度以及粘结剂的含量，使用热成像仪(InfraCAM，FLIR系统)检查导电层中的生热。
(1)根据粘结剂含量的生热图案
表3示出实施例1(粘结剂含量：0wt％)、实施例11(5wt％)、实施例7(10wt％)、实施例12(15wt％)和实施例13(20wt％)的导电织物的生热图案图。表3示出导电层的放热温度随着粘结剂含量的增加而增加。该导电织物的放热温度的增加归因于导电层的组成性无机组分与非导电性有机材料的混合造成导电层的电导性的恶化。从试验1的结果来判断，含粘结剂的导电织物在试验1中表现出提高的耐冲洗性，需要确定导电织物的耐冲洗性和电导性之间的最佳条件。鉴于前述内容，可以得出结论：最优选的粘结剂含量在10-15wt％的范围内。
表3
Figure G2007800416462D00141
(2)导电层线宽的影响
表4示出实施例7(线宽：1cm)和实施例17(2cm)的导电织物的生热图案。在实施例7的导电织物中于50℃观察到放热带，认为其是因为电荷没有容易地流经导电层。相反，在实施例17的导电织物中观察到放热温度的降低。
表4
Figure G2007800416462D00151
(3)导电层厚度的影响
表5示出实施例7(厚度：10μm)和实施例18(20μm)的导电织物的放热图案。在实施例7和18的导电织物中分别于45℃和29℃观察到放热带，表明导电织物的电导性受导电层的厚度影响。
表5
Figure G2007800416462D00152
4、拉伸强度的推测
根据ASTM D 5034-94标准方法，对实施例17和比较例1的导电织物进行拉伸试验。具体地，将每种导电织物剪成50±1mm(宽度)×150mm(长度)的尺寸。样品被分成A、B、C和D四个部分。对被分开的部分测量拉伸强度。使用测试仪(Instron 4444，IX系列)在下述条件下进行五次或更多测量，该条件为：荷载元(load cell)＝2kN，长度计＝75±1mm，连杆器(crosshead)速度＝300±10mm/min。结果如表6和图8a-8d所示。
此外，进行拉伸试验时，在将由夹子固定的每个样品的导电层图案与万用表的头连接后，对拉伸形变时的样品电阻进行时时测量。
表6的结果揭示各个实施例的导电织物和比较例1的导电织物之间拉伸强度和伸长率之间没有显著差别。尤其是，实施例7的导电织物的不同导电层图案就拉伸强度和伸长率而言表现出类似结果，表明导电层图案对导电织物的拉伸强度和伸产率没有影响。这些结果表明在导电织物上的自由印刷是可能的，而这意味着可以保证导电织物的动态耐磨性。
图13-16是示出在拉伸形变时，实施例7制造的导电织物的A、B和C部分的电阻变化的视图。该视图表明电阻值随着伸长的长度的增加而逐渐增加直至约20mm至约24mm并且此后开始陡然增加。这些观察意味着导电层被剪切。
尽管在此参考前述实施方式和附图已经描述了本发明，但本发明的范围由下附权利要求所限定。因此，本领域技术人员将理解各种替代、修改和改变是可能的，而不背离如所附权利要求中公开的本发明的精神。应理解的是该替代、修改和改变在本发明的范围内。
当然，特别地，应理解尽管说明书通篇只提及了智能服装，但本发明的导电织物可以用作电路板或电器件的一部分。
表6
Figure G2007800416462D00171

Claims (36)

1.一种导电织物，包括：
基层，其由合成的、再生的或天然纤维构成；
导电层，其形成于基层上以能够通过预设计的电图案自由形成；和
绝缘层，其形成于导电层之上以防止导电层损坏，
其中所述导电层具有一个或多个电路弯曲部分的增大部分，其宽度大于该电路的线性部分。
2.根据权利要求1所述的导电织物，进一步包括底层，其在所述基层和所述导电层之间形成以使所述基层的表面均一。
3.根据权利要求2所述的导电织物，其中所述底层由聚氨基甲酸酯、丙烯酸和硅树脂中至少一种树脂所形成。
4.根据权利要求2所述的导电织物，其特征在于，所述底层由带有拒水层的多层结构所形成。
5.根据权利要求1所述的导电织物，其中所述导电层由导电聚合物、碳、金属材料及它们与粘结剂的混合物中至少一种材料所形成。
6.根据权利要求5所述的导电织物，其中所述金属材料包括银。
7.根据权利要求5所述的导电织物，其中所述导电聚合物选自聚苯胺、聚吡咯、聚噻吩及其混合物。
8.根据权利要求5所述的导电织物，其特征在于，所述金属材料和所述粘结剂以重量比90∶10至80∶20混合以形成所述导电层。
9.根据权利要求5所述的导电织物，其中所述粘结剂选自聚氨基甲酸酯树脂、丙烯酸树脂、硅树脂、三聚氰胺树脂、环氧树脂及其混合物。
10.根据权利要求9所述的导电织物，其中所述粘结剂是水分散型聚氨基甲酸酯树脂。
11.根据权利要求1所述的导电织物，其中所述导电层具有厚度为2μm至500μm。
12.根据权利要求11所述的导电织物，其中所述导电层具有厚度为10μm至20μm。
13.根据权利要求1所述的导电织物，其中所述导电层具有宽度为10mm至20mm。
14.根据权利要求1所述的导电织物，其中所述绝缘层通过在导电层上涂覆、印刷或层压聚氨基甲酸酯、丙烯酸、硅、聚酯、聚氯乙烯和聚四氟乙烯中至少一种树脂而形成。
15.根据权利要求1所述的导电织物，其中所述增大部分具有圆形或卵形。
16.根据权利要求1所述的导电织物，其中所述导电织物在冲洗前后具有电阻差为0.5Ω至4Ω。
17.一种制造导电织物的方法，包括下述步骤：
在由合成的、再生的或天然纤维构成的基层上形成电流流经的导电层；和
在导电层上形成绝缘层以防止导电层损坏，
其中所述导电层具有一个或多个电路弯曲部分的增大部分，其宽度大于该电路的线性部分。
18.根据权利要求17所述的方法，进一步包括在所述基层上形成底层以保持所述导电层的厚度为恒定水平。
19.根据权利要求18所述的方法，其中所述底层由带有拒水层的多层结构所形成。
20.根据权利要求17所述的方法，进一步包括在形成导电层前使用压辊压延所述基层以使所述基层的表面平滑、产生所述基层的孔并且增强导电织物的抗挠性。
21.根据权利要求17所述的方法，进一步包括在压延步骤后使所述基层进行透气性防水/防水以产生所述导电层的孔并且增强导电织物的绝缘性、耐冲洗性和抗挠性。
22.根据权利要求18或19所述的方法，其中所述底层通过刀辊、过辊涂覆、浮刀涂覆、辊式刮刀涂覆所形成。
23.根据权利要求18或19所述的方法，其中所述底层由聚氨基甲酸酯、丙烯酸和硅树脂中至少一种树脂所形成。
24.根据权利要求17所述的方法，其中所述导电层由导电聚合物、碳、金属材料中及它们与粘结剂的混合物中至少一种材料所形成。
25.根据权利要求24所述的方法，其中所述金属材料包括银。
26.根据权利要求24所述的方法，其中所述导电聚合物选自聚苯胺、聚吡咯、聚噻吩及其混合物。
27.根据权利要求24所述的方法，其中所述导电材料和粘结剂以重量比90∶10至80∶20混合以形成导电层。
28.根据权利要求24所述的方法，其中所述粘结剂选自聚氨基甲酸酯树脂、丙烯酸树脂、硅树脂、三聚氰胺树脂、环氧树脂及其混合物组成。
29.根据权利要求28所述的方法，其中所述粘结剂为水分散型聚氨基甲酸酯树脂。
30.根据权利要求17所述的方法，其中所述导电层具有厚度为2μm至500μm。
31.根据权利要求30所述的方法，其中所述导电层具有厚度为10μm至20μm。
32.根据权利要求17所述的方法，其中所述导电层具有宽度为10mm至20mm。
33.根据权利要求17所述的方法，其中所述绝缘层通过在所述导电层上涂覆、印刷或层压聚氨基甲酸酯、丙烯酸、硅、聚酯、聚氯乙烯和聚四氟乙烯中至少一种树脂而形成。
34.根据权利要求33所述的方法，其中所述绝缘层通过干燥涂覆、热熔网点层压或凹版层压形成。
35.根据权利要求17所述的方法，其中所述增大部分具有圆形或卵形。
36.根据权利要求17所述的方法，其中所述导电织物在冲洗前后具有电阻差为0.5Ω至4Ω。
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RU2449069C2 (ru) 2012-04-27
CN101542039A (zh) 2009-09-23
RU2009118193A (ru) 2010-12-20
CA2669657A1 (en) 2008-05-22
EP2084324B1 (en) 2013-12-04
EP2084324A4 (en) 2010-05-19
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US8003198B2 (en) 2011-08-23
JP2010509108A (ja) 2010-03-25
KR20080043730A (ko) 2008-05-19

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