CN1471462A - 热纺织物 - Google Patents

热纺织物 Download PDF

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CN1471462A
CN1471462A CNA01818068XA CN01818068A CN1471462A CN 1471462 A CN1471462 A CN 1471462A CN A01818068X A CNA01818068X A CN A01818068XA CN 01818068 A CN01818068 A CN 01818068A CN 1471462 A CN1471462 A CN 1471462A
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yarn
temperature coefficient
positive temperature
textile according
thermal textile
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Ar
A·R·丁格理斯
E·沃利尼斯
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Milliken and Co
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Abstract

为了由电源产生热量，纺织物(310)至少一部分由导电纱线(12)制成。纺织物(310)具有导电纱线(12)或“加热器”。使用有传导特性和可裁剪间距的导电材料用以产生热量。发热纱线具有一个正温度系数，其纱线的电阻随着温度的增加和降低而分别加大或减少。“引导线”，譬如导电纱线(12)可用于给发热纱线提供电能。为了在使用譬如熨烫等过程中保护纺织物的使用性能，以及使纺织物电绝缘，纺织物上涂覆有涂层。

Description

热纺织物
背景技术：
本发明一般涉及由电能产生热量的纺织物。
当电流施加于导电纱线时就会产生热，把这种导电纱线加入到纺织物中就制作成我们都知道的热纺织物。
为了提供热生成的自我调节性能，可生成热的金属线已经用于纺织物中。一般情况下，自我调节导线是两根并联的导体，在两导体之间布置有热生成材料。当电施加在两导线之间时导线就产生热量。为了调节导线产生的热量，在导线之间的热生成材料应具有下列特性：温度增加电阻加大；温度降低电阻减小。然而，在现有的产品中导线和纺织品表现出不规律性，因此不能使用户满意。
因此，人们需要有自我调节的但不应用加热导线的热纺织物。
附图说明：
图1所示是用于本发明的一个加热器纱线的横截面的放大图。
图2A和图2B显示机织纺织品，其显示根据本发明的另一应用机织织物的实施方案。
图3A和图3B所示为根据本发明的另一用于编织物的实施方案的图示。
具体实施方式：
根据本发明，一个热纺织物或针织物，可能是机织物、针织或任何其它类似的纺织物。它至少由部分导电纱线制成，目的是由电源产生热。其中纺织物可以是平面状、柱状的或其它纺织结构。这种结构应该有传导性能的导电纱线(“加热器”)和利于裁剪的间隙，并且利用电能产生热。加热器可以沿机器方向也可以与机器方向交叉。可能有或可能没有多股导线(导线)，诸如纱线，连接到加热器上用来给加热器提供电流。为了机器的稳定性，热织物的结构中包含非导电纱线。
在本发明的一个实施方案中，像传统的纺织品生产一样，纺织物是连续、滚动制成的。随后裁剪成用于最终产品的合适的尺寸片。热织物可以放在织物外层内的指定层或可以是外层织物，诸如印制的装饰织物。
在本发明中，这些加热器是具有正温度系数的纱线(“PTC”)。PTC纱线是导电纱线，当温度升高或降低时，纱线的电阻亦会相应增加或减小。PTC纱线通常包括具有导电性能的PTC材料，其导电性能为当温度升高时，电阻增加，当电阻减小时，电阻减小。在一个实施方案中，PTC纱线是由一个低传导或非传导的纱芯和一个PTC材料的护套构成的。
一个纱芯/护套纱线，作为一种发热纱线适用于本发明的实施方案中。其在美国专利号为09/667,065，标题是“随电阻温度变化纱线”，申请日期为2000年9月29日，申请人为DeAngel等的专利中有详细描述。作为一个整体，此专利在此作为参考。
如PTC纱线10一样，纱芯/护套纱线作为一种发热纱线适用于本发明的实施方案在图1中被示出。如图1所示，PTC纱线10通常包含有一个芯纱11和一个具有正温度系数阻抗(PTCR)的护套12，还包括一个在护套12上的绝缘体13。如图中所示：PTC纱线10的横截面是一圆形，还可以预先设计纱线10的横截面为其它形状，使之适合于纺织物的构造，像椭圆、扁平或类似其它形状。
芯纱11一般是具有弹性和伸展性、适合于纺织的任何材料的纱线。芯纱11可以由各种合成纱线构成，譬如聚脂、尼龙、聚丙烯腈系纤维、人造纤维、凯夫拉尔、诺梅克斯、玻璃纤维或类似材料，或者可以由天然纤维，譬如棉、木、丝绸、亚麻或类似材料构成。芯纱11还可以由单纤维、多纤维或人造短纤维等构成。另外，芯纱11可以是扁平状、螺旋状或应用于纺织品中的任意形状的纱线。在一个实施方案中，芯纱11选用的是非传导材料。
具有正温度系数的电阻(PTCR)护套12，是一种随温度增高而电阻加大的材料。在本发明的一个实施方案中，如图1所示，护套12一般包括良导体21和热膨胀低传导(TELC)基质22混合构成。
良导体21在PTCR护套12中产生一个导电通路。该良导体21优选是颗粒状，譬如传导材料中的粒子、涂覆有传导涂层的球体、传导薄层、传导纤维或类似的传导材料一样。这些传导粒子、纤维、薄层由譬如碳、石墨、金、银、铜或其它类似的传导材料形成。涂覆有涂层的球体可以是玻璃、陶瓷、铜，其被涂覆有例如碳、石墨、金、银、铜或类似的传导材料。这些球体都是微型球体，在一个实施方案中，这些球体的直径大约在10-100微米之间。
TELC基质22的膨胀系数高于传导粒子21。使TELC基质22的材料随温度升高而膨胀，这样就能够使TELC基质22内的传导粒子21分离，传导粒子21的分离加大了PTCR护套12的阻抗。TELC基质22也是为了弹性程度的需要而被加入到纱线中。在一个实施方案中，TELC基质22是乙基丙烯酸脂(EEA)或EEA与聚乙烯的合成物。还有一些材料为了满足用作TELC基质22的材料的需要，包括但不局限于下列物质：聚乙烯、聚烯烃、聚乙烯的衍生物、热固塑料或热固材料。
PTCR护套12可以通过挤压、喷涂或其它方法给芯纱11涂覆上一层材料。选择特殊的良导体21(例如薄层、纤维、等等)就使纱线具有了不同温度一阻抗特性，同时也影响了PTCR护套12的机械特性。TELC基质22还可以在工作温度内抵抗和防止纱线的软化或熔化。已经确定，PTC纱线10的有效阻抗值可以根据想要的应用在大约在0.1欧/英寸-2500欧/英寸范围内任意改变。
根据本发明的一个实施方案，譬如，在涂覆到芯纱11上后通过辐射，TELC基质22可以为交叉缝合材料。在另一实施方案，用热固性聚合物作为TELC基质22。在又一实施方案中，它可防止在特殊温度下介质软化和起内部保险丝的作用，在超过规定温度的特定区域时TELC基质22的传导将切断。
绝缘体13是适用于纱线柔性的非传导材料。在一个实施方案中，绝缘体的膨胀系数与TELC基质22的膨胀系数非常接近。绝缘体13可以是热塑性塑料、热固性塑料或经过处理可以由热塑性变为热固性的材料，譬如聚乙烯。适用于绝缘体13的材料包括：聚乙烯、聚氯乙烯或类似材料。绝缘体13可以通过挤压、喷涂、缠绕、以及缠绕加热的方法敷于PTCR护套12上。
把电压施加于PTC纱线10上就会产生电流流过PTCR护套12，当PTC纱线10的温度增高时，PTCR护套12的电阻也加大。在TELC基质22中，PTC纱线10电阻增加是由于分离出传导颗粒21的TELC基质22的膨胀形成的，因此，使基质中的微通路沿纱线长的方向移动并且增加了PTCR护套的总电阻。这种特有的温度传导关系适合于特殊应用，例如，利用它的特性可以让传导率慢慢增加到给定值，到温度断点处迅速上升。
为了帮助PTC纱线的导电连接，加热和加压能使PTC材料软化使连接更完全。另外，在纺织物中，传导纱线可以预先涂覆高传导敷料以增强在纺织物中的导电连接。
为了使热量均匀，发热纱线之间可以有1-2英寸的间距，但只要不违背本发明的本质，这个间距还可以更大或更小。由于当PTC纱线温度升高会使PTC纱线的加热减少，使用PTC纱线作为加热器可以控制温度直接进入纺织物中。因此，当这种热纺织品的温度升高时其电阻就会增大，从而减少由这种热纺织物产生的热。当热纺织物的温度减小时其电阻就会减小，从而增加由热纺织物产生的热就会增加。
导线一般(但不总是)比加热器具有更好的传导性和更小的频率。在一个实施方案中，导线是高传导材料的纱线。在另一个实施方案中，导线可以是导电金属线，诸如镍、其具有和纺织物中纱线相同的截面。
任何非传导纱线可以被用于改善织物的机械构造，例如，纬纱中具有发热纱线的机织织物可以具有另外的非传导性纬纱纱线，以用来改善织物的机械稳定性。玻璃纤维或聚酰氨纱线可以在高温下应用。
发热织物还可以涂覆有电绝缘材料，以在譬如使用期间和熨烫过程中保护织物。涂料可以选用任何电绝缘聚合物和通过任何可用方式涂覆于加热器。涂料的厚度可以变化，但在一个实施方案中，涂层的厚度为从5mils-13mils。聚丙稀腈系纤维是一种适合的涂料是，因为它们具有高绝缘、可弹性和非粘性的特点。弹性可帮助织物保持手感。低粘性帮助涂层织物保持涂层后织物的透气程度，本发明的开放式构造尽可能给织物涂层，又使空气透气度没有大幅度减少或消除。透气性能对于舒适性是很重要的，例如衣料、座套、毯子的透气性。涂层还增加了织物的机械稳定性，这对于保证织物内导电连接尤其重要。涂层还赋予了纺织物防火、防水或其它保护特性。
参考图示2A和2B，它们分别是根据本发明的实施方案，显示机织织物210和220的图示。如图2A所示，纺织物210由多根非传导纱线13、一根连续的发热纱线11混合编织而成。在发热纱线11的两端施加一电压，纺织物210就会产生热。如图2B所示，织物220由多根发热纱线11、引导纱线12和非传导纱线13编织而成。在一个实施方案中，发热纱线11是一根连续纱线的节。织物220中的发热纱线11，以并联方式连接在引导纱线12之间。给织物220中的引导纱线12之间施加一电压，纺织物220就会产生热。
参考图3A和图3B，他们分别是根据本发明的实施方案，显示编织织物310和320。如图3A所示，纺织物310包含编织到织物上的非传导纱线13，上面还有发热纱线11。在发热纱线的两端施加一电压，热织物310就会产生热量。如图3B所示，纺织物320包括非传导导线13、发热纱线11和引导纱线12，发热纱线11以并联方式与引导纱线12连接。在纺织物中320给引导纱线12间施加一个电压，织物320就会产生热量。从织物310和320的图示看出：发热纱线11和引导纱线12，被编织进非传导纱线13的编织图案中。依本发明考虑，热纱线11和/或引导纱线12也可以用于加入织物310或320的编织回路中。
这样织物就要完成了，恰当的收尾技术要根据所用的纱线类型。对于毛圈织物，在基底中用传导纱线是最好的选择。
纺织物加热器比传统的金属线有很多优点，比如弹性、空气的透气性、快速加热、热分布均匀且又有纤细(“无线的”)的外形等。因为纺织物能折叠或缝合到一个结构中或成卷的形式，所以在一些实例中纺织物也可以简化最终产品的生产。PTC材料的发热纱线是可以自动调节热量并且通常优于传统的传导热材料。通过混合PTC材料，织物具有一个固定的控制装置，它可以简化或排除温度反馈或额外的温度控制电路的需要。

Claims (32)

1.一种热纺织物包括：至少一根非传导纱线，至少一根正温度系数的发热纱线；所述的非传导纱线和发热纱线被混合用于热纺织物中。
2.根据权利要求1所述的热纺织物，其中正温度系数的发热纱线的电阻值在0.1欧姆/英寸到2500欧姆/英寸。
3.根据权利要求1所述的热纺织物，其中正温度系数的发热纱线是一个有芯纱/护套的纱线。
4.根据权利要求3所述的热纺织物，其中护套是具有正温度系数的电阻材料。
5.根据权利要求4所述的热纺织物，其中正温度系数的发热纱线包含一个单丝芯纱。
6.根据权利要求4所述的热纺织物，其中正温度系数的发热纱线包含一个多丝芯纱。
7.根据权利要求4所述的热纺织物，其中正温度系数的发热纱线包含一个人造短纤维芯纱。
8.根据权利要求7所述的热纺织物，其中人造短纤维芯纱是并捻的人造短纤维。
9.根据权利要求4所述的热纺织物，其中在护套的热膨胀性低的传导基质中包括良导体。其中传导基质比导电体的膨胀系数高。
10.根据权利要求9所述的热纺织物，其中基质是交叉缝合的。
11.根据权利要求9所述的热纺织物，其中基质有明确的软化温度，当达到所选择的温度值时电源被切断。
12.根据权利要求1所述的热纺织物，其中正温度系数的发热纱线包含一个绝缘涂层。
13.根据权利要求1所述的热纺织物，还包括：涂覆在发热织物上面的绝缘涂层。
14.根据权利要求1所述的热纺织物，其中正温度系数的发热纱线的横截面为圆形。
15.根据权利要求1所述的热纺织物，其中正温度系数的发热纱线的横截面为椭圆形。
16.根据权利要求1所述的热纺织物，其中正温度系数的发热纱线的横截面为扁平。
17.根据权利要求1所述的热纺织物，还包括：至少一个连接到所述正温度系数发热纱线的可导电导线。
18.根据权利要1所述的热纺织物，还包括两根可导电导线，且其中所述正温度系数发热纱线在两根导电导线之间是导电的。
19.根据权利要求1所述的热纺织物，其中所述的热纺织物中至少有一根具有正温度系数的发热纱线包括多条具有正温度系数的发热纱线，还包括两根导电导线，且其中所述的正温度系数发热纱线在两根导电导线之间采用并联的导电连接。
20.根据权利要求1所述的热纺织物，其中所述热纺织物是机织织物。
21.根据权利要求20所述的热纺织物，还包括至少一根导电导线连接到所述正温度系数发热纱线。
22.根据权利要求20所述的热纺织物，还包括两根导电导线，其中所述的正温度系数发热纱线导电连接在两根导电导线之间。
23.根据权利要求20所述的热纺织物，其中所述的至少一根正温度系数发热纱线包括多条正温度系数发热纱线，还包括两根导电导线，且其中所述的正温度系数发热纱线以并联方式在两根导电导线之间导电连接。
24.根据权利要求1所述的热纺织物，其中所述的热纺织物是编织织物。
25.根据权利要求24所述的热纺织物，其中所述的发热纱线构成所述织物的回路。
26.根据权利要求24所述的热纺织物，其中所述的发热纱线置于所述的非传导纱线的回路中。
27.根据权利要求24所述的热纺织物，还包括至少一根导电导线连接到所述的正温度系数发热纱线。
28.根据权利要求24所述的热纺织物，其中所述导线包含一根传导纱线，其中所述热纺织织物包含一编织物，且其中所述的传导纱线构成所述编织物回路。
29.根据权利要求24所述的热纺织物，其中所述的传导导线置于所述的非传导纱线的回路中。
30.根据权利要求24所述的热纺织物，其中所述的热纺织物包括一个编织物，且其中所述的导线置于所述的非传导纱线的回路中。
31.根据权利要求24所述的热纺织物，还包括两根导电导线，且其中所述的正温度系数发热纱线在两根导电导线之间是导电连接的。
32.根据权利要求24所述的热纺织物，其中所述的至少一根正温度系数发热纱线包含多条正温度系数发热纱线，还包括两根导电导线，且其中所述的正温度系数发热纱线在两根导电导线之间以并联方式导电连接。
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