CN112011886A

CN112011886A - Knitted structure for generating and distributing heat

Info

Publication number: CN112011886A
Application number: CN201910470901.XA
Authority: CN
Inventors: P·W·亚力山大; N·L·约翰逊; K-H·陈; N·D·曼卡姆; S·C·朗; M·S·福斯; S·M·科迪-甘普
Original assignee: GM Global Technology Operations LLC
Current assignee: GM Global Technology Operations LLC
Priority date: 2019-05-31
Filing date: 2019-05-31
Publication date: 2020-12-01

Abstract

The knit structure is configured to generate and distribute heat. In some embodiments, the knitted structure comprises a knitted fabric comprising a first knitted layer and a second knitted layer opposite the first knitted layer. The first knit layer has a first thermal conductivity. The second knitted layer has a second thermal conductivity. The second thermal conductivity is greater than the first thermal conductivity to facilitate heat transfer to the first knit layer. The knitted construction may further include a plurality of electrodes disposed at least partially within the knitted fabric. Each of the plurality of electrodes is configured to generate heat within the knit fabric upon receipt of electrical energy so as to spread the heat along the knit structure and toward the first knit layer.

Description

Knitted structure for generating and distributing heat

Technical Field

The present disclosure relates to knit structures for generating and distributing heat.

Background

In some applications, it is desirable to spread heat through the knit structure. For example, a vehicle seat may include a knitted textile that may require heating. For this reason, it is desirable to develop a knitted structure capable of generating and distributing heat.

Disclosure of Invention

The knit structure is configured to generate and distribute heat. In some embodiments, the knitted structure comprises a knitted fabric comprising a first knitted layer and a second knitted layer opposite the first knitted layer. The first knit layer has a first thermal conductivity. The second knitted layer has a second thermal conductivity. The second thermal conductivity is greater than the first thermal conductivity to facilitate heat transfer to the first knit layer. The knitted construction may further include a plurality of electrodes disposed at least partially within the knitted fabric. Each of the plurality of electrodes is configured to generate heat within the knit fabric upon receipt of electrical energy so as to spread the heat along the knit structure and toward the first knit layer. The second knitted layer may include a plurality of insulating yarns. The second knitted layer may include a plurality of infrared reflective yarns. The knitted construction may further comprise an intermediate knitted layer arranged between the first knitted layer and the second knitted layer. The intermediate knit layer may include a plurality of resistively heated yarns to facilitate heat transfer to the first knit layer. The intermediate knit layer may include a plurality of infrared-producing yarns to facilitate heat transfer to the first knit layer. The first knit layer may include a plurality of infrared transparent yarns to provide a heated surface. The first knit layer may include a plurality of infrared transparent yarns to provide a purely radiant heating surface. By defining porosity on the first knit layer, the first knit layer can include a plurality of infrared transparent yarns and a plurality of infrared absorbing yarns. The knit structure can define a gap between the first knit layer and the second knit layer to allow air to flow through the gap. The second knitted layer may include a plurality of insulating yarns to facilitate heat transfer toward the first knitted layer. The knitted construction may further comprise an intermediate knitted layer arranged between the first knitted layer and the second knitted layer. The intermediate knit layer may include a plurality of resistively heated yarns to facilitate heat transfer toward the first knit layer. The first knit layer can include a plurality of infrared absorbing yarns to provide a heated surface. The first knit layer includes a plurality of infrared transparent yarns to provide a radiant heating surface.

In some embodiments, the knitted structure includes a first knitted layer, a second knitted layer, and a knitted spacer fabric interconnecting the first knitted layer and the second knitted layer. Further, the knitted structure includes a thermoelectric device (TE) disposed within the knitted structure. The knit structure defines a pocket sized to receive the thermoelectric device. The thermoelectric device is closer to the second knitted layer than the first knitted layer. Thermoelectric devices are configured to convert electrical energy directly into a temperature differential for heating or cooling. The knitted spacer fabric includes a network of thermally conductive yarns directly interconnecting the pocket and the first knitted layer to transfer heat from the thermoelectric device to the first knitted layer. A similar thermally conductive network can be knitted into the second knitted layer to serve opposite sides of the thermoelectric device, so each side of the thermoelectric device has an effective heat sink structure. The knitted construction may further include at least one power conductor disposed inside the second knitted layer and electrically connected to the thermoelectric device to supply power to the thermoelectric device. The pocket is partially defined by the second knitted layer. The knitted construction further includes a covering knit layer directly joined to the second knit layer to form the pocket. The thermoelectric device may also be operated in the reverse mode to cool the first knitted layer while heating the second knitted layer.

In some embodiments, a knit structure includes a knit body including a first knit layer and a second knit layer. The knitted body defines a conduit between the first knitted layer and the second knitted layer to allow fluid to flow through the knitted body. The knitted body is configured to be flat for shipping. The knitted body includes fusible yarns to allow for unfolding for assembly. The knitted construction may further comprise a knitted spacer fabric between the first knitted layer and the second knitted layer.

The above features and advantages and other features and advantages of the present teachings are readily apparent from the following detailed description of the best modes for carrying out the teachings when taken in connection with the accompanying drawings.

Drawings

Figure 1 is a schematic cross-sectional view of a knitted structure for generating and distributing heat.

Figure 2 is a schematic partial cross-sectional view of the knitted construction shown in figure 1.

Figure 3 is a schematic partial cross-sectional view of the knitted construction shown in figure 1.

Fig. 4 is a schematic cross-sectional side view of the knit structure of fig. 1 including a pocket for a thermoelectric device.

Fig. 5 is a schematic illustration of a first knit layer of the knit structure of fig. 4.

Figure 6 is a schematic illustration of a second knitted layer of the knitted construction of figure 4.

Figure 7 is a schematic illustration of a knitted spacer fabric of the knit structure of figure 4.

Fig. 8 is a schematic illustration of a knit structure defining an integrally knit catheter.

Figure 9 is a schematic cross-sectional view of the knitted construction of figure 8 taken along section line a-a.

Figure 10 is a schematic partial enlarged view of the knitted construction of figure 8 taken along the area b.

Figure 11 is a schematic isometric view of the knitted structure of figure 8 shown flat for transport.

Fig. 12 is a schematic perspective view of the knit structure of fig. 8 shown as having been deployed for installation and/or use.

Detailed Description

Referring to the drawings, wherein like reference numbers correspond to like or similar components throughout the several figures, and beginning with FIG. 1, a knit structure 10 can be used to generate and distribute heat. In the present disclosure, the term "knitted" does not include woven materials; conversely, the term "knitted" refers to a textile produced by knitting. By way of non-limiting example, the knitted structure 10 may be a packaging for a Heating Ventilation and Air Conditioning (HVAC) system to provide efficient heat transfer. However, it is contemplated that the knitted construction 10 may be used to effectively transfer heat toward a desired surface. For example, the knitted construction 10 may be a seat (such as a vehicle seat) that can efficiently transfer heat to a heated surface to provide heat to a seated occupant during cold climates. Knitted structure 10 includes a knitted fabric 12 and a plurality of electrodes 14 disposed at least partially within knitted fabric 12. For example, the electrodes 14 may be knitted and/or embedded in the knitted fabric 12. The electrodes 14 are configured to receive electrical energy from one or more power sources 16, which may be considered part of the knitted structure 10. By way of non-limiting example, the power source 16 is configured as one or more battery cells. The electrode 14 is electrically connected to a power supply 16 and ground 18. Thus, the electrodes 14 may receive electrical energy from the power source 16. Upon receiving electrical energy from the power source 16, the electrodes 14 are configured to generate heat within the knit fabric 12 to distribute the heat along the knit structure 10. In the depicted embodiment, the electrodes 14 are disposed within only some (but not all) portions of the knitted fabric 12 to generate and distribute heat along the targeted locations of the patterned electrical power delivery arrangement. However, it is contemplated that the electrodes 14 may be positioned to spread heat along the entire knitted structure 10. The knitted construction 10 may be used for electrical heating and/or seat warming. It is also contemplated that the knitted construction 10 may be used to direct heat to specific areas to defog a window.

Referring to fig. 2, the knitted fabric 12 includes a first knitted layer 20 and a second knitted layer 22 opposite the first knitted layer 20. The first knit layer 20 may be made of polyester and has a first thermal conductivity. The second knit layer 22 has a second thermal conductivity greater than the first thermal conductivity to facilitate heat transfer to the first knit layer 20. As discussed above, the electrodes 14 are disposed inside the knitted fabric 12, and thus heat can be generated within the knitted fabric 12, spreading the heat along the knitted fabric 12 towards the first knitted layer 20. It is desirable to distribute heat to the first knit layer 20 to provide comfort, for example, to a seated occupant of a vehicle seat (i.e., knitted structure 10). Alternatively, it may be desirable to distribute heat to the first knit layer 20 to provide, for example, an energy efficient package for an HVAC system (i.e., the knit structure 10).

With continued reference to fig. 2, to facilitate spreading heat toward the first knit layer 20, the second knit layer 22 includes a plurality of thermally insulative yarns and/or infrared-reflective yarns (i.e., second layer yarns 24). In the present disclosure, the term "insulating yarn" refers to a yarn made primarily of an insulating material. As a non-limiting example, the insulating yarn may be made in whole or in part of polyoxadiazole fiber to provide optimal heat resistance. In the present disclosure, the term "infrared-reflective yarn" refers to a yarn that is capable of reflecting infrared radiation to prevent heat transfer. To this end, the fibers forming the infrared-reflective yarn may be coated with an infrared-reflective coating. As a non-limiting example, the polymer fibers forming the infrared-reflective yarn may be coated with a metal coating (e.g., an aluminum coating) to provide infrared radiation reflection. Additionally or alternatively, the polymer fibers forming the infrared-reflective yarn may be coated with an infrared-reflective pigment.

With continued reference to fig. 2, the knitted fabric 12 further includes an intermediate knit layer 26 disposed between the first knit layer 20 and the second knit layer 22. In the depicted embodiment, the intermediate knit layer 26 directly interconnects the first and second knit layers 20, 22 to facilitate heat transfer to the first knit layer 20. The intermediate knit layer 26 includes a plurality of resistively heated yarns and/or infrared-producing yarns (i.e., intermediate layer yarns 28) to facilitate heat transfer to the first knit layer 20. In the present disclosure, the term "resistively heated yarn" refers to a yarn that is capable of converting all or at least a majority of the electrical energy received by the yarn into heat. Thus, the resistance heated yarn is able to absorb heat. As a non-limiting example, the resistance heating yarn includes, but is not limited to, silver coated polyimide yarn. In the present disclosure, the term "infrared ray-generating yarn" refers to a yarn that is capable of absorbing heat from the electrode 14 and spreading infrared radiation. To this end, the intermediate layer yarns 28 may be in thermal communication with (e.g., in direct contact with) the electrodes 14. By way of non-limiting example, the infrared-producing yarn may be made wholly or partially of polyamide 6.6 yarn.

With continued reference to fig. 2, the first layer of knitting 20 includes a plurality of infrared light transparent yarns and/or infrared light absorbing yarns (i.e., intermediate layer yarns 28) to distribute heat H from the first layer of knitting 20 in a direction away from the second layer of knitting 22. In the present disclosure, the term "infrared transparent yarn" refers to a yarn that allows infrared radiation to pass through. As a result, heat absorbed by the intermediate layer yarns 28 can be readily transferred from the first knitted layer 20 in a direction away from the second knitted layer 22. In certain embodiments, the first knit layer 20 includes only infrared transparent yarns to provide a purely radiant heating surface to enhance comfort in, for example, a vehicle seat. By way of non-limiting example, the infrared transparent yarns comprise synthetic polymer fibers having inherently low IR absorption, such as polyethylene-based yarns. As discussed above, the first layer of knitting 20 may (alternatively or additionally) include a plurality of infrared light absorbing yarns to spread heat H from the first layer of knitting 20 in a direction away from the second layer of knitting 22. In the present disclosure, the term "infrared light absorbing yarn" refers to a yarn that is capable of absorbing infrared radiation to increase the temperature of the first knit layer 20. By way of non-limiting example, the infrared absorbing yarn may comprise polymer fibers, which may be coated with an infrared absorbing pigment, such as carbon black or a chitin resin. In certain embodiments, the first knit layer 20 may be made of only infrared absorbing yarns for providing a heating surface, which may maximize the efficiency of the HVAC package. Alternatively, by defining porosity on the first knit layer, the first knit layer 20 includes a plurality of infrared transparent yarns and a plurality of infrared absorbing yarns, thereby allowing the knit fabric 12 to provide a heated surface and radiate heat H from the first knit layer 20.

Referring to fig. 3, the knitted construction 10 defines a gap between the first knitted layer 20 and the second knitted layer 22 to allow air a to flow through the gap 30 defined between the first knitted layer 20 and the second knitted layer 22. As a result, the air flowing through the gap 30 can be heated, thereby maximizing the efficiency of, for example, a HAVC system.

Referring to fig. 4 to 6, the multi-bed knitted structure 10 includes a first knitted layer 20, a second knitted layer 22, and a knitted spacer fabric 32 interconnecting the first knitted layer 20 and the second knitted layer 22. As shown in fig. 5, the second knitted layer 22 may be configured as a network of heat conductive yarn fins 46. A similar heat conducting network can be knitted into the second knitted layer 11 to serve opposite sides of the thermoelectric device, so each side of the thermoelectric device has an effective heat sink structure. The network of thermally conductive yarn fins 46 may maximize the rate of heat transfer into or out of the second knitted layer 22. The second knitted layer 22 may be knitted on the first needle bed. The first knitted layer 20 serves as a radiator layer to supply heat to, for example, a vehicle seat. As shown in fig. 6, the first knit layer 20 can be knit on a second bed of needles to form a thermal yarn mesh 48 for contact with a passenger (e.g., a seated passenger in direct contact with the first knit layer 20).

The knitted spacer fabric 32 elastically biases the first knitted layer and the second knitted layer away from each other. One or more thermoelectric devices 34 are disposed within the multi-bed knitted structure 10. In the present disclosure, the term "thermoelectric device" refers to a device that employs the peltier effect to convert a voltage directly into a temperature difference (or vice versa). In this embodiment, the knitted construction 10 defines a pocket 36 shaped and dimensioned to receive the thermoelectric device 34. Specifically, the multi-bed knitted structure 10 provides an integrated position-defining and securing feature (i.e., pocket 36) for the thermoelectric device 34. The multi-bed knitted structure 10 allows the thermoelectric devices 34 (which are rigid) to be spaced apart from rough contact with objects or persons (i.e., passengers) that directly contact the first knitted layer 20. One or more power leads 38 are electrically connected to the thermoelectric device 34 and the power source 16. Power supply 16 is connected to ground 18. The power cord 38 is knitted or inlaid in the second knitted layer 22. The thermoelectric device 34 may receive voltage from the power supply 16 via power leads 38. Thus, the power supply wire 38 is arranged inside the second knitted layer 22 and electrically connected to one face of the thermoelectric device 34 to supply power to the thermoelectric device 34. Upon receiving a voltage from the power supply 16, the thermoelectric device 34 generates heat. Thus, the thermoelectric device 34 is configured to directly convert electrical energy into a temperature differential. The thermoelectric device 34 may also be used to cool a surface.

With continued reference to fig. 4-6, to avoid making rough physical or thermal contact with an object or person (i.e., a passenger) directly contacting the first layer of knitting 20, the thermoelectric device 34 is closer to the second layer of knitting 22 than the first layer of knitting 20. Specifically, the thermoelectric device 34 may be disposed entirely within the pocket 36 to properly retain and position the thermoelectric device relative to the desired heating surface (i.e., the outer surface 21 of the first knit layer 20). In the vehicle seat, the outer surface 21 of the first knitted layer 20 is a surface facing a seated occupant. The pocket 36 is defined in part by the second knit layer 22 and the overlying knit layer 40 that is directly connected to the second knit layer 22 to maintain the thermoelectric device 34 in a desired position. The cover knit layer 40 is in direct contact with the thermoelectric device 34 to facilitate heat transfer between the thermoelectric device 34 and the cover knit layer 40. The thermoelectric device can also be operated in the reverse mode to cool the first knit layer 20 while heating the second knit layer 22.

With continued reference to fig. 4-7, knitted spacer fabric 32 includes a plurality of non-thermally conductive yarns 42. Further, the knitted spacer fabric 32 includes a network 44 of thermally conductive yarns (see also fig. 6) that directly interconnect one side of the pocket 36/face of the TE device 36 (specifically, the overlying knitted layer 40) and the first knitted layer 20 to transfer heat to or from the thermoelectric device 34 to the first knitted layer 20. To this end, the network 44 of thermally conductive yarns comprises thermally conductive yarns 47 directly interconnected to the overlying knitted layer 40 (which in part defines the pockets 36). In the present disclosure, the term "thermally conductive yarn" refers to a yarn that is capable of (and in fact facilitates) heat transfer. Thus, the thermally conductive yarn 47 thermally couples the thermoelectric device 34 to the first textile layer 20. The first knitted layer 20 and the second knitted layer 22 are not in physical contact with each other. Further, the first and second

knitted layers

20 and 22 are not in electrical contact with each other to avoid short circuits.

Referring to fig. 7, knitted spacer fabric 32 may be a polyester sample and include thermally conductive yarns 47 and non-thermally conductive yarns 42 surrounding thermally conductive yarns 47 to maximize the rate of heat transfer from thermoelectric devices 34 (fig. 4) to first knitted layer 20. Thermally conductive yarns 47 may be arranged in first yarn section 50 and second yarn section 52. The density of thermally conductive yarns 47 in second yarn section 52 is greater than the density of thermally conductive yarns 47 in first yarn section 50, thereby maximizing the rate of heat transfer from thermoelectric device 34 (fig. 4) to first textile layer 20. Further, first yarn section 50 surrounds second yarn section 52, thereby maximizing the heat transfer rate from thermoelectric device 34 (fig. 4) to first knit layer 20. The thermally conductive yarns 47 in the first yarn region 50 are arranged sparsely, but are directly connected to each other along the X-direction and the Y-direction. The second yarn region 52 may surround the pocket 36.

Referring to fig. 8-12, the multi-bed knitted structure 10 may define an integrally knitted conduit 54 for HVAC and aerospace applications. The multi-bed knitted structure 10 may also be used for brake ducts and other applications requiring directional air flow delivery. No special tools are required to produce knitted structure 10. Instead, a single knitting machine can produce a knitted structure 10 having many geometries. Further, the knitted construction 10 may be knitted as one piece, even for complex, branched and/or overlapping geometries. The knitted construction 10 includes a knitted body 13 including a first knitted layer 20 and a second knitted layer 22. The knitted body 13 defines one or more integral knitted conduits 54 between the first knitted layer 20 and the second knitted layer 22 to allow fluid to flow through the knitted body 13. As shown in fig. 11, the knitted body 13 is configured to be flat for shipping and then (as shown in fig. 12) may be unfolded for installation and/or use, allowing for flexible and efficient manufacturing. The knitted body 13 is made in whole or in part of fusible yarns 33 to secure the desired shape of the knitted body 13 after it is deployed (fig. 12). To expand, the knitted body 13 is inflated through the integrated knitted duct 54 and subjected to a steaming process to fix the shape of the fusible yarn 33. As a result, the fusible yarn 33 is bonded and hardened. The fusible yarn 33 also prevents the sealing surface from leaking. The fusible yarn 33 may be made wholly or partly of a low melting polyamide or copolyester. The knitted body 13 may be integrated into a trim of a vehicle, such as a roof.

The knitted construction 10 may include a knitted spacer fabric 32. The gap is defined by a knitted spacer fabric 32 between the first knitted layer 20 and the second knitted layer 22 to allow fluid to flow through the gap 30. The insulating material may be knitted into the knitted body 13. The knitted body 13 can define an open knit outlet 56 that extends through the second knitted layer 22. The mesh knit outlet 56 can deliver fluid (e.g., air) to a target location. In addition, the knitted body 13 can define through-holes 58 that extend through the cells of the cell knit outlet 56.

While the best modes for carrying out the teachings have been described in detail, those familiar with the art to which this disclosure relates will recognize various alternative designs and embodiments for practicing the teachings within the scope of the appended claims. The knit structures illustratively disclosed herein may suitably be practiced in the absence of any element that is not specifically disclosed herein. In addition, the characteristics of the embodiments shown in the drawings or the various embodiments mentioned in the present specification are not necessarily to be understood as embodiments independent of each other. Rather, it is possible that each feature described in one example of an embodiment may be combined with one or more other desired features from other embodiments to yield yet further embodiments that are not described in text or with reference to the accompanying drawings. For example, all or some of the features of the knitted construction 10 described in fig. 1 to 3 may be combined with all or some of the features of the knitted construction 10 described in fig. 4 to 7 and/or all or some of the features of the knitted construction 10 described in fig. 8 to 12.

Claims

1. A knit structure for generating and distributing heat, comprising:

a knit fabric comprising a first knit layer and a second knit layer opposite the first knit layer, wherein the first knit layer has a first thermal conductivity, the second knit layer has a second thermal conductivity, and the second thermal conductivity is greater than the first thermal conductivity to facilitate heat transfer toward the first knit layer; and

a plurality of electrodes disposed at least partially inside the knit fabric, wherein each of the plurality of electrodes is configured to generate heat within the knit fabric upon receipt of electrical energy so as to spread heat along the knit structure and toward a first layer of knit.

2. The knitted structure according to claim 1, wherein the second knitted layer includes a plurality of insulating yarns.

3. The knitted structure according to claim 1, wherein the second knitted layer includes a plurality of infrared-reflective yarns.

4. The knitted construction of claim 1, further comprising an intermediate knitted layer disposed between the first knitted layer and the second knitted layer, wherein the intermediate knitted layer includes a plurality of resistively heated yarns to facilitate heat transfer toward the first knitted layer.

5. The knitted construction of claim 1, further comprising an intermediate knit layer disposed between the first knit layer and the second knit layer, wherein the intermediate knit layer includes a plurality of infrared producing yarns to facilitate heat transfer toward the first knit layer.

6. The knitted construction of claim 1 wherein the first knit layer includes a plurality of infrared transparent yarns to provide a heated surface.

7. The knitted structure according to claim 1, wherein the first knitted layer includes a plurality of infrared transparent yarns to provide a pure radiant heating surface.

8. The knitted construction of claim 1, wherein the first knit layer includes a plurality of infrared transparent yarns and a plurality of infrared absorptive yarns for defining porosity on the first knit layer.

9. The knitted construction of claim 1, wherein the knitted construction defines a gap between a first knitted layer and a second knitted layer to allow air flow through the gap, the second knitted layer including a plurality of insulating yarns to facilitate heat transfer toward the first knitted layer, the knitted construction further including an intermediate knitted layer disposed between the first knitted layer and the second knitted layer, the intermediate knitted layer including a plurality of resistive heating yarns to facilitate heat transfer to the first knitted layer, the first knitted layer including a plurality of infrared absorbing yarns to provide a heated surface, and the first knitted layer including a plurality of infrared transparent yarns to provide a radiant heated surface.

10. A knitted structure comprising:

a first knitted layer;

a second knitted layer;

a knitted spacer fabric interconnecting the first knitted layer and the second knitted layer; and

a thermoelectric device disposed inside the knit structure, wherein the knit structure defines a pocket sized to receive the thermoelectric device.