DE102009010415A1 - Spacer fabric for use as e.g. seat heating mat in motor vehicle, has individual electrically conductive resistor wire that is attached at one of poles of electrical voltage supply and comprises electrical insulating layer over entire length - Google Patents

Abstract

The fabric has upper and lower cover layers (1, 2) held at a distance by bending resistant and bending elastic threads i.e. warp threads (3), of defined length by forming an intermediate layer. An individual electrically conductive resistor wire i.e. power strand, is inserted and moved back and froth into a heating zone during knitting of fabric continuously according to type of filling thread in the intermediate layer in a meander-shaped knitting direction. The wire is attached at one of poles of an electrical voltage supply and has an electrical insulating layer provided over entire length. An independent claim is also included for a knitting machine comprising a thread guide.

Description

The invention relates to a spacer fabric according to the preamble of claim 1. Such a spacer fabric with a heating zone by the utility model DE 29901225 U1 known. The invention further relates to the knitting machine for its production of the spacer knit according to claim 12.

In this case, a spacer knitted fabric is knitted with two outer layers which are held at a distance by bending-resistant and bending-elastic plastic filaments (vertical filaments) of a certain length to form an intermediate layer. When working a single electrically conductive resistance wire (conductor strand) is endless in the manner of a weft thread in the intermediate layer ( three ) transversely to the direction of action straight and registered in the direction of meandering back and forth. The wire ends of the resistance wire can be connected to one of the poles of an electrical voltage source.

This spacer fabric has the disadvantage that only heating pad can be made with a small length and width, otherwise the heating power is too low. The well-known spacer fabric takes the distance knitted fabric after the DE 4239068 C "To the model in which a plurality of electrical conductors are incorporated as a chain in the spacer knitted fabric and connected transversely to the manufacturing direction of the spacer knit connecting conductors. In this case, the described disadvantages do not occur.

The Invention has the object, the mentioned disadvantage of the known Spacer knit to avoid.

When Solution has turned out to be unexpected, that the Resistance wire over its entire length with an electrical insulating layer must be provided when the heating pad also suitable for motor vehicle seats Should have size.

The invention is thus in contrast to all previously known Sitzheizkissen, including those that are not made as Abstandsgewirke but as a textile surface with only one layer, and those that consist of two parallel layers with inserted therebetween heating, z. B. DE 10326446 B4 and DE 19342285 B4 ,

It was not recognized in the prior art that everywhere where a plurality of parallel filaments through the ends of the filaments guided contact threads be charged with electrical energy, the heating filaments because of their relatively low Length can be applied only with low electrical voltage must, and every filament because of the large number the parallel heating wires leads only a small current. The insulation within the spacer fabric or on the textile Base area was therefore sufficient.

With the knitting industry, stand process for the production of spacer textiles to disposal. This will be two textile fabrics simultaneously in one operation as two spaced cover layers, d. H. a top / (front) and a bottom / (back) side produced and in their production a so-called monofilament made of plastic, standing to the top and bottom, alternately in the top and bottom / front and back involved.

This Monofilament, in this application as a spacer thread or filament is an endless filament, in appearance a fishing line comparable, the monofilament is made of a suitable plastic, z. B. polyester / polyethylene terephthalate desired thickness and a high, permanent intrinsic elasticity and stiffness Compression and bending load.

It So is a rigid and bend-elastic plastic wire. It is shrinkproof by suitable treatment, in particular heat setting made. Because both cover layers by a large number such Stehfäden connected and supported against each other are, the cover layers are held apart elastically, so that between them one of the vertical threads or produced with a certain inclination penetrated intermediate layer, can be produced and usable in a thickness of up to 30 mm.

The physical properties of the standing thread are chosen such that the distance between the two cover layers through the length and inherent stability of the standing threads is defined.

By the elastic properties of the standing threads becomes the spacer textile with vertical surface pressure on one of the cover layers elastically compressed, so that the thickness decreases depending on the force. When pressure is released, the standing threads quickly return to their original state Form back, so that is the actually defined distance the cover layers reached again. The principle of operation is with a Compression spring comparable.

to Spacer textiles are used primarily as or on seating surfaces and lying areas.

spacer fabrics will improve the ventilation of the body contact surfaces on seat and backrests are placed.

It is also known, the outer layers with To produce (very) open network structure and to use such a spacer fabric as a support for a conventionally produced heating mat (consisting of fleece top and textile heating surface with incorporated heating and contact conductors made of carbon and or metal filaments and non-woven underside). Such combinations of spacer fabric and heating mat are then z. B. used as a seat heaters and sewn or glued between the cushion layers.

The Invention has advantage, such three-dimensional, voluminous Spacer textiles with sufficient heatability and a To provide a process for its preparation, wherein the product in cost-effective in a single rational, low-cost process be produced and also be versatile should.

there the electrical conductor is already in the production of the spacer textiles inserted in the intermediate layer, so that the parallel strands this ladder is across the width or length of the spacer fabric, a grid of desired density form and by applying an electrical voltage for heating can serve. by using the conductor as a resistance wire will and when creating one for its length heated sufficiently high voltage. In this Design serves the spacer fabric as versatile Heating mat, especially as a seat or backrest heaters for Motor vehicles or furniture, heated mattress or mattress topper, Wall heating, heated wall or wall cover for mobile thermoboxes, possibly with electrical connection for car / truck on-board electrical system, heated mats possibly with electrical connection for Car / caravan / boat-board electrics.

Without further voluminous cushions an unpleasant close contact with the body is avoided, good climate physiological properties (eg dissipation of moisture) achieved, a heat transfer and preventing the formation of sweat air movement below the uppermost upholstery possibly also approved by a blower:
The advantages of the spacer fabric as a heating mat result from the influenced by the nature of the network structure air flow and convection, but also from the vapor and moisture permeability, which may be desirable especially when used as a mattress, mattress pad or mat. The mesh structure of the cover layers and the permeability of the intermediate layer allows easy cleaning and washing.

Of the Network structure character of such spacer textiles with open, net-like cover surfaces can - in the technical representable borders - made with any width become. This description of the properties and advantages of the invention Spacer textiles meet in a specific way devices for Spacer knitted fabric too.

The Insertion of the conductor into the intermediate layer of the spacer textiles According to this invention is done transversely to the progress direction of the resulting spacer textile (in a spacer knitted fabric speaks one from "shooting direction"). The ladder is an endless one Wire, which is between the side edges of the spacer fabric and runs around and a grid with a predetermined distance of the Wire strands forms. The wire is made by a novel special thread guide entered, the between the side edges back and forth. Because of the relatively sharp reversal The side edges is preferred as a conductor in this type of installation a metal wire, in particular copper wire or one of a wire bundle existing strand used. After cutting the endless fabricated spacer fabric is formed at each of its longitudinal ends a wire end. These two ends of the wire are connected to an electrical Voltage source connectable.

The electrical voltage source can be connected in a simple manner; there is no further work step for attaching a contact conductor required. There is no danger of short circuit between parallel running wire strands.

Because of the heat and air distribution are spacer textiles after This invention according to claim 8, in particular as a seat heating mats advantageous for motor vehicles.

The Heat conduction not only by radiation but also by Convection with simultaneous thermal insulation favors the use of spacer textiles according to this invention according to claim 9 as a wall cover especially for holding or heating tank with electricity. Such containers can be for keeping warm and heating food in motor vehicles carry and use, because the energy needs because of the good Heat insulation and transmission also by the Power supply of a motor vehicle can be covered.

Because of the heat and air distribution are spacer textiles after This invention according to claim 10, in particular as mattresses or mattress pads or according to claim 11 as heated Reclining mats or edition of a heated mat can be used.

Especially with the latter uses, the invention is advantageous according to claim 1, since the network structure of the outer layers and the permeability of the intermediate layer a simple cleaning and washing and moisture does not lead to short circuits. By designing the utility structure, the heat transfer when used as a heating mat in a valuable frame can be influenced.

to Preparation of a spacer knit according to this invention is the Knitting machine according to claim 12 equipped with a driven yarn guide, the transverse to the direction of progress of the knitted fabric, the needle movement following the guide bar, while moving an electrical conductor, in particular Copper wire or copper wire entails and this after predetermined Repeat alternately in the upper (front) and lower (rear) the cover layers incorporates.

in the Next, the invention will be described with reference to a spacer fabric Example described. (The terms spacer fabric and Spacer knit used synonymously.)

It demonstrate:

1 the scheme of a spacer textile

2 the scheme of a spacer knitted fabric with inserted conductor

three the scheme of a spacer knitted fabric with inserted conductor

4 the scheme of a knitting machine for the manufacturing process.

A spacer textile consists of two cover surfaces 1 and 2 which are simultaneously produced on a machine, ie woven, knitted or knitted. In this case, alternately in the upper or front and the lower or rear cover layer, a spacer thread is bound in a specific repeat, so that the two cover layers by a plurality of evenly spaced spacer threads (Stehfäden) three are connected.

z:

Richtung der Länge = Herstellrichtung, Fortschrittsrichtung,

x:

Abstand der Deckschichten

y:

Breite des Textils

The coordinates indicate

z:

Direction of length = direction of manufacture, direction of progress,

x:

Distance of the cover layers

y:

Width of the textile

There it is the spacer threads to an elastic monofilament with a certain rigidity and - after buckling or Bend - a good recovery, arises between the cover layers a lasting intermediate layer, the is penetrated by the spacer threads. Therefore, when The upper cover layer is elastically elastic under load compressible; after a decrease in the load, the upper springs Cover layer back to its original position.

The Finishes can be more or less dense, especially also be produced reticulated.

2 corresponds largely to the 1 , Shown schematically is a spacer fabric with a type of conductor not according to the invention.

Between the cover layers 1 and 2 is in the interlayer three introduced a plurality of electrical conductors simultaneously with the production of the two cover layers and the integration of the spacer threads. These electrical conductors are distributed at a distance from each other across the width B of the knitted fabric. These may be wire bundles or wire strands of metal or carbon. The introduction can be done in a straight line, so that the conductors have a constant distance to each other. However, the conductors can also be inserted with a reciprocating motion across their direction of installation. Each conductor thereby forms a sinusoid which may be in phase or out of phase with the narrow of the adjacent conductor. When using the conductors as resistance heating wires (heating mat), this results in a surface heat distribution.

The group of conductors is after cutting the fabric in parallel with a voltage source 6 connected. For this purpose, on each side of the ends of the ladder through a contact wire 5 connected with each other. It can be seen that here the individual conductor wires between their connecting wires have a small length, so that at low voltage already flows a high current.

In three It is shown that according to the invention, only one electrical conductor transverse to the direction of progress of the outer layers in a certain repeat by a guided between the ingot yarn guide between the side edges (width B) of the knit back and forth. It also creates a grid of substantially parallel to each other conductor strands. In this embodiment, preferably metal or copper wires are used as a conductor, as they can be redirected without risk of breakage. The two ends of the conductor become after cutting the knit with a voltage source 6 through contact wire 5 connected. It can be seen that here the conductor has a considerable length.

Therefore the total resistance is greater and it must to Achieving the desired heating power a larger Voltage applied so that the required current flows.

Of the conductive wire, according to this invention as a conductor or contact wire is used, has on its surface an insulating layer similar to coil wire, z. B. by wrapping with an electrically insulating plastic layer or by wrapping with insulating threads.

By the invention is - even in the intended use as sitzheizkissen, heating mattress, heated mat, etc. - avoided that this higher voltage leads to losses, eg. B. by the - although low - conductivity of the textile material, but especially by moisture. In this way it is possible, the conductor already in the production of the spacer fabric in the manner of a weft thread in the intermediate layer ( three ) transversely to the direction of action straight without looping and meandering in the direction of action back and forth insert and connect with its two wire ends to one of the poles of the electrical voltage source.

Where the spacer fabric serves as a heating mat depends on their heating effect from the density, with the conductor strands next to each other are laid. The use is also largely due to the technical design of the cover layers and by the distance the cover layers influenced.

4 shows the scheme of a knitting machine for the manufacturing process. Shown are guide bars three 10 a Raschel machine. The two outer guide bars are used to produce the cover layers, the remaining guide bars for the action of the spacer threads. There are - arranged perpendicular to the drawing surface (= Y direction) a plurality of such guide bars behind each other. Below the guide bar are the front and rear tee bars 8.1 . 9.2 as well as the front and rear needle bar, 9.1 and 9.2 , The spacer fabric 7 arises with width B (= Y direction, also referred to as the goods width), length L (= Z direction, also referred to as effective direction, progress direction, active progress and as the direction of origin). and thickness D (= X direction). Below the guide bar is a thread guide 12 on a rail 13 movably guided and driven. In this case, the mouth of the thread guide the needle movement follow substantially over the entire width of the fabric, while an electrically conductive externally insulated heating wire 4 Insert into the resulting spacer fabric without the heating wire participating in the stitch formation. The insertion takes place substantially in the Y direction and substantially rectilinear, ie at a uniform speed. In the end regions of the fabric width, however, the thread guide reverses with a defined acceleration and deceleration so that the heating wire is laid here in an arc. Then the return path takes place, wherein the heating wire is again laid in a straight line and in the Y direction. This continues until the end of Konfektionsende to be produced with a certain clothing length heating pad, heating mat, heating mat o.

It is now the subject of a further invention to continue the knitting process beyond the clothing length and to produce an excess length of the spacer fabric with the heating wire inserted therein. The spacer fabric can then be cut in the region of the excess length in the Y direction over the entire width. Then, the heating wire is released from the excess length of the spacer wire and the spacer fabric is dissolved. As a result, a sufficient length of the heating wire is ready to connect the beginning and end of lying in a clothing length of the heating pad heating wire with the closely spaced poles of an electrical voltage source. The heating wire / resistance wire 4 is on a freely rotatable or braked rotatable feed bobbin 11 saved. By the with the active progress and with the laying movement of the thread guide 13 Enlarging distance of the points of integration relative to the supply spool, the heating wire is continuously withdrawn from the supply spool.

1

Floor space, upper (front) top surface

2

Floor space Top surface, lower (rear) top surface

3

linking Thread systems, standing threads, monofilaments, spacer threads

4

Ladder, Conductor strand, wire, wire bundle, wire strand, stranded wire

5

Contact conductor, Contact wire, wire

6

Voltage source, electric S.

7

spacer

8th

Barre discount

8.1

front Barre discount

8.2

rear Barre discount

9

Needle bar,

9.1

front needle bar

9.2

rear needle bar

10

guide bar

11

supply bobbin

12

X axis

movement direction the guide bar through the needle gaps, direction of the distance the knock-over bar and the thickness (D) of the spacer knit, orientation of the heating wire guide

Y-axis

extension direction all bars in the direction of the working width of the machine and width of goods (B) of the spacer knit, moving direction of the Heizdrahtführers

Z axis

direction the lifting movements of the needle bar and the length (L) of the Spacing fabrics, goods progress direction, direction of progress the production,

B

Product width (B) of the spacer knit

D

thickness (D) of the spacer knit

L

length (L) of the spacer knit

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• - DE 29901225 U1 [0001]
• - DE 4239068 C [0003]
• - DE 10326446 B4 [0006]
• - DE 19342285 B4 [0006]

Claims (12)

Spacer knit with two outer layers ( 1 . 2 ), which by bending stiff and bending-elastic threads (standing threads three ) are held at a certain length to form an intermediate layer at a distance, and with a heating zone in which a single electrically conductive resistance wire (conductor strand 4 ) when working the spacer knit endlessly in the manner of a weft thread in the intermediate layer ( three ) - transversely to the direction of action straight without stitch formation and - in the direction of meandering back and forth is entered, and connected with its two wire ends to one of the poles of the electrical voltage source is characterized in that the resistance wire is provided over its entire length with an electrical insulating layer , Spacer knitted fabric according to claim 1, characterized that the insulating layer of the resistance wire by spinning with an insulating heat-resistant plastic thread he follows. Spacer knitted fabric according to claim 1, characterized that the insulating layer of the resistance wire by insulating heat-resistant plastic coating takes place. Spacer knitted fabric according to claim 1, characterized that the resistance wire is beaten from insulated wire strands and additionally on its outer circumference with a Insulating layer is surrounded. Spacer fabric according to claim 1, characterized in that that the resistance wire is a copper wire. Spacer fabric according to claim 1, characterized in that that the resistance wire is a wire bundle of copper wire or copper wire strands is. Spacer knitted fabric according to claim 1, characterized that the resistance wire consists of a bunch of copper wires or carbon filaments or copper wire strands and a steel wire core. Spacer knitted fabric according to claim 1, characterized by Use as a seat heating mat for motor vehicles. Spacer knitted fabric according to claim 1, characterized by Use as a wall covering, in particular for keeping warm or heating tank with power connection. Spacer knitted fabric according to claim 1, characterized by Use as mattress or mattress pad. Spacer knitted fabric according to claim 1, characterized by Use as a heated hammock or pad of a heated Sleeping pad. Knitting machine for producing a spacer knitted fabric with two outer layers and inlaid isolated electrical Resistance wire according to claim 1, characterized in that the resistance wire presented on a freely rotatable or braked rotatable feed bobbin and is guided by a yarn guide, which Following the needle movement of the needle bar following an installation movement, by crossing the direction of progress of the knitted fabric (active progress) moved back and forth, with the resistance wire in places with Mesh one of the outer layers connected (integration) and through the with the active progress and with the laying movement of the thread guide increasing distance of sites of integration withdrawn continuously from the supply spool relative to the supply spool becomes.