CN113829690A - 一种发热布及其织造方法 - Google Patents

一种发热布及其织造方法 Download PDF

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CN113829690A
CN113829690A CN202010571176.8A CN202010571176A CN113829690A CN 113829690 A CN113829690 A CN 113829690A CN 202010571176 A CN202010571176 A CN 202010571176A CN 113829690 A CN113829690 A CN 113829690A
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heating
electrode
wires
base cloth
flexible carbon
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梅山标
沈守兵
黄熠
陈秀苗
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Shanghai Shuixing Home Textile Co Ltd
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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
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    • B32—LAYERED PRODUCTS
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    • B32—LAYERED PRODUCTS
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
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    • B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B9/047—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material made of fibres or filaments
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D1/00—Woven fabrics designed to make specified articles
    • D03D1/0088—Fabrics having an electronic function
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D13/00—Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft
    • D03D13/008—Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft characterised by weave density or surface weight
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
    • H05B3/34—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater flexible, e.g. heating nets or webs
    • H05B3/342—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater flexible, e.g. heating nets or webs heaters used in textiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/546—Flexural strength; Flexion stiffness

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  • Ceramic Engineering (AREA)
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Abstract

本发明为一种发热布及其织造方法。所述发热布包括基布层、若干个发热单元、和开关控制单元，所述发热单元分成若干个分布在所述基布层上或整个覆盖在所述基布层上，所述发热单元包括相连的柔性碳发热丝、分别由电极丝组成的正电极和负电极，所述柔性碳发热丝连于所述正电极和负电极之间，所述柔性碳发热丝、电极丝与所述基布层相互编织而成，所述基布层和发热单元的外表面设有保护层；所述电极丝与所述开关控制单元相连；所述柔性碳发热丝平行分布在所述基布层中。

Description

一种发热布及其织造方法
技术领域
本发明涉及一种家纺用布，特别是公开一种发热布及其织造方法。
背景技术
在社会生产力早已完全满足生存需要的时候，人们便开始更新消费观念，追求新颖、时尚、功能性的物质，床品这种传统生活用品也在面临新的挑战，并不断做出突破和创新，以满足人们日益迫切的健康和享乐需求。
床单作为一种常用的床寝用品，由具有良好亲夫性的布片制成，通常是铺放在床垫上面来作为睡觉时的垫层，为了在冬天有效驱寒保暖，通常会对床单进行加厚磨毛处理或者在床单下边垫放褥子或者电热毯来提高保暖效果，但都会对舒适性和亲肤性产生较大影响，电热毯垫在床单下部的结构同样会影响床单正常使用时的舒适性，且使用传统电热毯还具有一定的安全隐患。传统的电热毯或发热床垫构造十分简单，基本结构包括柔性面料和发热组件，发热组件以电热丝为主，成本虽低，但电热转化效率简陋，导热性、安全性和舒适性均难以控制，也无法针对特殊的需要而局部发热。发热组件通过电路板与电源相连，电路板控制发热组件发热。
发明内容
本发明的目的在于克服现有技术中存在的缺陷，提供一种可水洗、耐弯折、能安全高效地自行发热的发热布及其织造方法。
本发明是这样实现的：一种发热布，包括基布层、若干个发热单元和开关控制单元，所述发热单元分成若干个分布在所述基布层上或整个覆盖在所述基布层上，所述发热单元包括相连的柔性碳发热丝、分别由电极丝组成的正电极和负电极，所述柔性碳发热丝连于所述正电极和负电极之间，所述柔性碳发热丝、电极丝与所述基布层相互编织而成，所述基布层和发热单元的外表面设有保护层；所述电极丝与所述开关控制单元相连；所述柔性碳发热丝平行分布在所述基布层中。
所述保护层为PU薄膜层或PET博膜层或纺织面料层。
所述柔性碳发热丝的加捻捻度为200 -600捻/米，纤度＜500旦。
所述柔性碳发热丝在所述基布层中的分布密度为60-500根/10厘米。
所述正电极、负电极中各有4-20根电极丝作为经纱与基布层、柔性碳发热丝交织相连，电极丝的末端拧成一股与所述开关控制单元相连。
所述柔性碳发热丝在碳纤维发热丝、石墨烯发热丝、碳纳米管发热丝或炭黑发热丝中任选一种。
所述电极丝为柔性铜电极线，所述正电极和负电极之间的间隔距离为30-100厘米。
一种如上所述的一种发热布的织造方法，包括如下步骤：
S1、用常规织布机，按照常规工艺调整，综数量、穿纱及上机参数；
S2、用棉纱作为基布层纺纱的经纱和纬纱；柔性碳发热丝作为纬纱；发热单元的正电极和负电极各用4-20根电极丝作为经纱，所述电极丝分别与棉纱、柔性碳发热丝交织，形成带有发热单元的基布层；所述电极丝的末端拧成一股留出形成发热单元连接端；其中，柔性碳发热丝加捻捻度为200 -600捻/米，纤度＜500旦，密度为60-500根/10厘米；
S3、基布两侧通过胶黏法或热压法贴附厚度小于或等于2丝的保护层，其中，所述保护层为PU薄膜、PET薄膜或者纺织面料层；
S4、将所述发热单元连接端与开关控制单元连接，并将开关控制单元固定在所述保护层上。
所述开关控制单元为带有变压器的开关控制单元。
步骤S2中，所述棉纱为10S~ 60S的棉纱。
本发明的有益效果是：本发明发热布既能保证布片本身的亲肤舒适性、耐水洗性、耐弯折性等日用性能，也能安全高效的自行发热，并且根据实际需要，发热单元可完全覆盖整块布片，也可划分区域独立分布，柔性碳发热丝即可经向分布，也可纬向分布。本发明发热布可制成发热床单、发热枕套、发热沙发套等日用织品。
附图说明
图1是本发明结构示意图。
其中：1、基布层；2、发热单元；3、供电单元；4、开关控制单元；5、柔性碳发热丝；6、电极丝；7、正电极；8、负电极；9、保护层。
具体实施方式
根据图1，本发明一种发热布，包括基布层1、若干个发热单元2、和与供电单元3电连接的开关控制单元4，所述发热单元2分成若干个分布在所述基布层1上或整个覆盖在所述基布层1上，所述发热单元2包括相互连接的柔性碳发热丝5、分别由电极丝6组成的正电极7和负电极8，所述柔性碳发热丝5连于所述正电极7和负电极8之间，所述柔性碳发热丝5、电极丝6与所述基布层1相互交织而成，所述柔性碳发热丝5的加捻捻度为200 -600捻/米，优选 300 捻/米，纤度＜500旦。所述柔性碳发热丝5在所述基布层1中的分布密度为60-500根/10厘米，优选220根/10厘米。所述正电极7、负电极8中各有4-20根电极丝6作为经纱与基布层1、柔性碳发热丝5交织相连，所述柔性碳发热丝5平行分布在所述基布层1中。电极丝6的末端拧成一股通过开关控制单元4与所述供电单元3相连形成通路。所述电极丝6为柔性铜电极线，所述正电极7和负电极8之间的间隔距离为30-100厘米，优选 50 厘米。
所述基布层1和发热单元2的外表面设有保护层9；所述保护层9为PU薄膜层或PET博膜层或纺织面料层。所述电极丝6与所述开关控制单元4相连，所述开关控制单元4与所述供电单元4相连；所述供电单元3为电压≤36V的低压单元，可以采用直流电或交流电。所述开关控制单4元为带有变压器的开关控制单元。所述开关控制单元4可采用上海大丰电源科技有限公司生产的、型号为JCSH-100-C的控制单元。
本发明一种发热布的织造方法，包括如下步骤：
S1、用常规织布机，按照常规工艺调整，综数量、穿纱及上机参数。
S2、用棉纱作为基布层纺纱的经纱和纬纱；柔性碳发热丝作为纬纱；发热单元的正电极和负电极各用4-20根电极丝作为经纱，所述电极丝分别与棉纱、柔性碳发热丝交织，形成带有发热单元的基布层；所述电极丝的末端拧成一股留出形成发热单元连接端；其中，柔性碳发热丝加捻捻度为200 -600捻/米，纤度＜500旦，密度为60-500根/10厘米；所述棉纱为10S~60S的棉纱，优选21S的棉纱。所述柔性碳发热丝在碳纤维发热丝、石墨烯发热丝、碳纳米管发热丝或炭黑发热丝中任选一种。
S3、基布两侧通过胶黏法或热压法贴附厚度小于或等于2丝的保护层，其中，所述保护层为PU薄膜、PET薄膜或者纺织面料层。
S4、将所述发热单元连接端与带有变压器的开关控制单元连接，并将开关控制单元固定在所述保护层上。
在步骤S1中，采用常规织布机操作，按照组织结构及穿综方式设置用综数量、穿纱及上机工艺参数，根据穿纱顺序穿纱，调整卷布辊到和钢筘的距离，张力设定时要根据前梁到后梁纱线的张力均匀度也即是纱线松紧来作调整。穿纬纱时，碳纤维纱线的引纬时间和频率可通过仪器设置。钢筘的总长与坯布幅宽保持一致，钢筘密度为55-160筘/5cm，筘入数为2-4入，经纱根数=钢筘长度/钢筘密度×筘入数。穿筘时起始和结尾段的筘入数要大于设定值，起到锁边的作用，可采用2-5入/筘。
所述柔性碳发热丝是一种纯黑体材料，属于电阻式加热，具有升温迅速、热滞后小、发热均匀、热辐射传递距离远、热交换速度快等特点，其中电热转化效率比常规金属发热提高30%，电热效率近乎100%。在相同的允许的电流负荷面积下。柔性碳发热丝化学性能稳定，耐腐蚀，不易被氧化，在无氧状态下加热到3000度，其机械性能不发生任何变化，在电热状态下克服了金属丝、PTC、碳化硅电热体强度低，易氧化烧断的缺点。并且柔性碳发热丝寿命长，强度远高于金属发热丝，在电热过程中抗拉强度没有什么改变。柔性碳发热丝断线不起弧有效杜绝火灾的发生。本发明在不影响布片本身使用性能的前提下，将柔性碳发热丝应用和融合到本发明中，通过对编织方法的改进，将柔性碳发热丝与棉纱的结合，让本发明发热布具有自行发热保暖的性能。本发明发热布可制成发热床单、发热枕套、发热沙发套等日用织品。本发明发热布既能保证布片本身的亲肤舒适性、耐水洗性、耐弯折性等日用性能，也能安全高效的自行发热，并且根据实际需要，发热单元可完全覆盖整个床单，也可划分区域独立分布，柔性碳发热丝即可经向分布，也可纬向分布。

Claims (10)

1.一种发热布，其特征在于：包括基布层、若干个发热单元和开关控制单元，所述发热单元分成若干个分布在所述基布层上或整个覆盖在所述基布层上，所述发热单元包括相连的柔性碳发热丝、分别由电极丝组成的正电极和负电极，所述柔性碳发热丝连于所述正电极和负电极之间，所述柔性碳发热丝、电极丝与所述基布层相互编织而成，所述基布层和发热单元的外表面设有保护层；所述电极丝与所述开关控制单元相连；所述柔性碳发热丝平行分布在所述基布层中。
2.根据权利要求 1 所述的一种发热布，其特征在于：所述保护层为PU薄膜层或PET博膜层或纺织面料层。
3.根据权利要求 1 所述的一种发热布，其特征在于：所述柔性碳发热丝的加捻捻度为200 -600捻/米，纤度＜500旦。
4.根据权利要求 1 所述的一种发热布，其特征在于：所述柔性碳发热丝在所述基布层中的分布密度为60-500根/10厘米。
5.根据权利要求 1 所述的一种发热布，其特征在于：所述正电极、负电极中各有4-20根电极丝作为经纱与基布层、柔性碳发热丝交织相连，电极丝的末端拧成一股与所述开关控制单元相连。
6.根据权利要求 1或5 所述的一种发热布，其特征在于：所述柔性碳发热丝在碳纤维发热丝、石墨烯发热丝、碳纳米管发热丝或炭黑发热丝中任选一种。
7.根据权利要求 1 或5所述的一种发热布，其特征在于：所述电极丝为柔性铜电极线，所述正电极和负电极之间的间隔距离为30-100厘米。
8.一种如权利要求1-7中任意一项所述的一种发热布的织造方法，其特征在于：包括如下步骤：S1、用常规织布机，按照常规工艺调整，综数量、穿纱及上机参数；
S2、用棉纱作为基布层纺纱的经纱和纬纱；柔性碳发热丝作为纬纱；发热单元的正电极和负电极各用4-20根电极丝作为经纱，所述电极丝分别与棉纱、柔性碳发热丝交织，形成带有发热单元的基布层；所述电极丝的末端拧成一股留出形成发热单元连接端；其中，柔性碳发热丝加捻捻度为200 -600捻/米，纤度＜500旦，密度为60-500根/10厘米；
S3、基布两侧通过胶黏法或热压法贴附厚度小于或等于2丝的保护层，其中，所述保护层为PU薄膜、PET薄膜或者纺织面料层；
S4、将所述发热单元连接端与开关控制单元连接，并将开关控制单元固定在所述保护层上。
9.根据权利要求8所述的一种发热布的织造方法，其特征在于：所述开关控制单元为带有变压器的开关控制单元。
10.根据权利要求8所述的一种发热布的织造方法，其特征在于：步骤S2中，所述棉纱为10S~60S的棉纱。
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CN115506068A (zh) * 2022-10-21 2022-12-23 常州市碳维观致智能科技有限公司 一种用于保暖的碳纤维发热器、碳纤维发热布料的制造工艺

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* Cited by examiner, † Cited by third party
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CN115506068A (zh) * 2022-10-21 2022-12-23 常州市碳维观致智能科技有限公司 一种用于保暖的碳纤维发热器、碳纤维发热布料的制造工艺
CN115506068B (zh) * 2022-10-21 2024-03-01 常州市碳维观致智能科技有限公司 一种用于保暖的碳纤维发热器、碳纤维发热布料的制造工艺

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