JP5962021B2 - Conductive fabric and method for producing the same - Google Patents

Description

  The present invention relates to a conductive fabric and a method for producing the same, and more particularly to a conductive yarn termination technique that is not used for energization in a conductive fabric including a conductive yarn in a fabric made of non-conductive yarn. is there.

  A conductive fabric in which a conductive yarn is made of a non-conductive yarn is known, and is used for applications such as heaters and various sensors using conductivity. For example, this type of conductive fabric is used as a seat skin (seat cover) of a vehicle seat, and is used as a seat skin provided with a seat heater or a capacitive seating sensor.

  When energizing a conductive fabric including a conductive yarn, the conductive yarn is often connected to a conductive connecting member at the end of the conductive fabric. The connecting member is further connected to a power source, a control device, and the like. In the raw fabric of the conductive fabric, the conductive yarn exists in a state surrounded by a structure made of non-conductive yarn, and before connecting the conductive yarn to the connecting member, the end of the conductive yarn is connected to the edge of the fabric. Need to be exposed from.

  As a method for exposing the end of the conductive yarn from the fabric edge of the conductive fabric, the method described in Patent Document 1 is known. This is because the cloth material partly composed of conductive wire is removed by removing other wire (non-conductive yarn) that is more easily burned or melted than the conductive wire using a heating means represented by laser. This is a method of exposing the connected portion of the wire. When there is a first conductive wire to be energized and a second conductive wire to be de-energized as the conductive wire, the connected portion of the second conductive wire is removed by burning or melting by the heating means Only the connected portion of the first conductive wire is exposed. FIG. 5 shows a schematic diagram of the conductive fabric in this state. The conductive yarn (first conductive wire) 42a for the energization extends from the fabric edge 41a of the conductive fabric 41 to expose the conductive member. The end portion of the unused conductive yarn (second conductive member) 42b is cut at the position of the fabric edge 41a.

JP 2010-261143 A

  However, only by cutting the unused conductive yarn 42b at the position of the fabric edge 41a of the conductive fabric 41, the cut surface of the unused conductive yarn 42b cut at the fabric edge 41a of the conductive fabric 41 is exposed. Therefore, it easily comes into contact with the connecting member and the neighboring conductive yarn 42a for energization, and an electrical connection is formed between them. Even if the cut surfaces of the unused conductive yarns 42b do not come into contact with those members in the connecting step of the connecting member, the conductive fabric 41 or the connecting member is bent and deformed, for example, while the conductive yarn 42a is energized. When such a force is applied, the cut surface of the unused conductive yarn 42b easily contacts the connecting member or the neighboring conductive yarn 42a for energization, and current flows through the connecting member through the unused conductive yarn 42b. There is a possibility that a short circuit may occur between the non-conductive conductive yarn 42b and the conductive conductive yarn 42a that is in close proximity. Even if the outer peripheral surface of the conductive yarn 42 is covered with a resin material or the like in advance to form a conductive fabric, the conductive material is exposed on the cut surface, and these phenomena may occur.

  Therefore, it is possible to use a method of attaching the connecting member after covering the portion where the unused conductive yarn 42b is cut at the position of the fabric edge 41a with an insulating member such as an insulating tape-like cloth material. Then, although insulation with respect to the connection member of the cut surface of the unused conductive yarn 42b can be ensured, an insulating member which is a separate member is required, and it is necessary to attach the insulating member by sewing or the like. It will increase. In particular, when the output of the heater is adjusted by the number (density) of conductive yarns to be energized, a plurality of conductive yarns 42a and non-use conductive yarns 42b are provided adjacent to each other in several units. The number of parts that must be covered with a small area insulating member for every several conductive yarns is increased, the number of parts and the number of processes increase by the number of insulating parts, and the attaching work of the insulating member is remarkable. It becomes complicated. The probability that defects such as forgetting to install the insulating member or incomplete mounting will increase.

  Further, it is necessary to attach the insulating member, and the insulating member may be visible to the user and the design may be deteriorated, or the insulating member may give the user a sense of foreign matter.

  The problem to be solved by the present invention is an insulating member that is a separate member when a conductive connecting member is connected to a conductive yarn that conducts a part of current in a conductive fabric including a conductive yarn and a non-conductive yarn. It is an object of the present invention to provide a conductive fabric that can insulate an end portion of a conductive yarn that is not energized without using a connecting member and a conductive yarn that is energized nearby and a method for manufacturing the same.

  In order to solve the above problems, the conductive fabric according to the present invention includes a conductive yarn and a non-conductive yarn, and a part of the plurality of conductive yarns is an unused conductive yarn that is not energized. The gist of the present invention is that the end of the unused conductive yarn is covered with an insulating member made of a material derived from non-conductive yarn constituting the conductive fabric.

  In this case, an end portion of the unused conductive yarn may extend outward from an end edge of the conductive fabric, and the extended portion may be covered with the insulating member.

  Furthermore, it is preferable that an end portion of the unused conductive yarn is covered with a constituent material of the nonconductive yarn which has been melted and re-solidified.

  In addition, the method for producing a conductive fabric according to the present invention includes a conductive yarn and a non-conductive yarn, and a part of the conductive yarn is a conductive yarn for energization with the conductive material at the end exposed, and the remaining conductive yarn. In the method for producing a conductive fabric which is an unused conductive yarn whose end is insulated and coated, a laser beam is applied to the region made of the non-conductive yarn surrounding the end of the conductive yarn for energization under the injection of assist gas. To remove the non-conductive yarn surrounding the conductive conductive yarn by melting or burning, thereby exposing the conductive material constituting the conductive conductive yarn, and the end of the non-conductive conductive yarn. By irradiating the region of the non-conductive yarn surrounding the portion with the laser beam in a state where the intensity of the laser beam and / or the flow rate of the assist gas is lower than in the first step, the end portion of the non-use conductive yarn Melt the non-conductive yarn surrounding the The formed material is resolidified in a state of covering the end portion of the unused conductive yarn, and summarized in that an insulating member covering an end portion of the unused conductive yarn.

  According to the conductive fabric according to the invention, the end portion of the unused conductive yarn is covered with the insulating member made of the material derived from the nonconductive yarn constituting the conductive fabric, and is electrically insulated. Therefore, even if the conductive yarn for energization arranged in the vicinity thereof is connected to a member such as a conductive connecting member and energized, the unused conductive yarn whose end is covered is connected to the connecting member and other conductive yarns. On the other hand, it is electrically insulated and is not energized through the connecting member, and does not cause a short circuit due to contact with the energized conductive yarn in the vicinity. Furthermore, since the insulating member is a material derived from the non-conductive yarn of the conductive fabric, there is no need to use a separate insulating material such as a tape-shaped fabric material, and a heating means is used in the conventional conductive fabric. Thus, the number of parts is reduced as compared with the case where the unused conductive yarn is cut and the cut portion is insulated with a tape-like insulating member or the like. There is no need for mounting for the insulating member, and the insulating member does not deteriorate the design or give the user a sense of foreign matter.

  In this case, when the end portion of the unused conductive yarn extends outward from the fabric edge and the extended portion is covered with the insulating member, the conductive yarn for energization is connected to the connecting member for connection to the connection member. When extending from the fabric end to the outside, it is not necessary to cut the unused conductive yarn at the position of the fabric edge after uniformly extending the ends of all the conductive yarns outward from the fabric edge. Since the unused conductive yarn is electrically insulated without being cut, the manufacturing process of the conductive fabric is simplified.

  Further, when the end of the unused conductive yarn is covered with the constituent material of the nonconductive yarn that has been melted and re-solidified, the dense insulating coating covers the end of the unused conductive yarn, Obtain high electrical insulation. Further, such an insulating member can be formed by a simple method in which the non-conductive yarn is melted and allowed to cool in a state where the ends of the unused conductive yarn are covered.

  In addition, according to the method for producing a conductive fabric according to the invention, it is necessary to cut the end portion of the unused conductive yarn in order to form the electrical insulation of the unused conductive yarn. Therefore, the number of steps required for insulating the unused conductive yarn is reduced and the operation is facilitated as compared with the conventional method. Furthermore, by simply controlling the intensity of the laser beam and / or the flow rate of the assist gas, the exposure of the conductive member at the end portion of the conductive yarn for energization and the formation of the insulating member at the end portion of the non-use conductive yarn are common. Since it can carry out continuously using an apparatus, while the number of processes in the whole manufacturing process of conductive cloth is reduced, the number of necessary facilities is also controlled. In addition, even when unused conductive yarns and energizing conductive yarns are adjacent and there are many, formation of an insulating member at the end of the unused conductive yarn and exposure of the conductive member at the end of the energized conductive yarn Can be performed with high positional accuracy.

It is a front view of the electroconductive fabric concerning 1st embodiment of this invention. The state which attached the connection member to the fabric edge of the conductive fabric of FIG. 1 is shown, (a) is a front view, (b) and (c) are AA sectional views and B- It is B sectional drawing. It is the schematic which shows the manufacturing method of the electroconductive fabric concerning 1st embodiment of this invention, and the attachment method of a connection member. It is a front view of the electroconductive fabric concerning 2nd embodiment of this invention. It is a front view of the conductive fabric manufactured by the manufacturing method of the conventional conductive fabric.

  First, the detail of the electroconductive fabric concerning 1st embodiment of this invention is demonstrated based on FIG.1 and FIG.2. FIG. 1 shows a front view of a conductive fabric 1 according to the first embodiment of the present invention. The conductive fabric 1 according to the present embodiment can be suitably used as a heater device disposed on the skin of a vehicle seat that itself generates heat to be a heater device or on the back side of a seat cover.

  The conductive fabric 1 has a conductive yarn 2 and a non-conductive yarn. As the conductive yarn 2, it is possible to use fibrous materials having various conductivity such as a conductive wire made of only a thin metal wire or other conductive material, or a conductive yarn made of a composite material of these conductive wire and other fibers. it can. However, as will be described later, when the non-conductive yarn arranged around the end portion of the unused conductive yarn 2b is melted by laser light irradiation, the conductive wire constituting the conductive yarn 2 is not cut. In addition, it is necessary to select a conductive material constituting the conductive yarn 2 having a melting point, a sublimation point, and a combustion point that are higher than the melting point of the non-conductive yarn constituting the conductive fabric 1. In this respect, it is preferable to select a fine metal wire as the conductive wire. It is particularly preferred to use a stainless steel wire having high tensile strength and corrosion resistance. The metal thin wire may be a single wire or a stranded wire. Moreover, the outer periphery may be coated with a resin or the like.

  As the non-conductive yarn, it is possible to use various highly insulating fiber materials, but since it is necessary to melt and coat the end surface of the unused conductive yarn 2b, a non-conductive yarn that is easy to melt is used. There is a need. Specifically, it must have a melting point lower than the temperature in the laser light irradiation region described later, and the combustion point and sublimation point in air must be higher than the melting point. In this respect, a thermoplastic resin is suitable.

  The conductive fabric 1 includes a conductive yarn 2 and a non-conductive yarn, and may be configured in any manner such as a knitted fabric, a woven fabric, or a non-woven fabric. In this embodiment, it is formed as a woven fabric, and the conductive yarns 2 are arranged in a substantially straight line at equal intervals as part of the warp or weft. When the conductive yarn 2 is energized, the conductive yarn 2 generates heat, and the conductive fabric 1 functions as a planar heater device. It is desirable that the conductive yarn 2 does not appear on the surface of the conductive fabric 1 so that other members, the user's body, and the like do not contact the conductive yarn 2. In each drawing, the non-conductive yarn is not clearly drawn in the conductive fabric 1, but the region other than the portion where the conductive yarn 2 is arranged is constituted by the non-conductive yarn.

  When the conductive fabric 1 is formed by cutting a long fabric into a shape necessary for various uses, a desired heating amount may vary depending on the use. For example, although it is used as a vehicle seat heater, a desired amount of heating differs depending on the part of the seat. In this case, not all the conductive yarns 2 are energized, but the conductive yarns 2a for energization and the non-conductive conductive yarns 2b that are not energized are provided periodically, and the ratio (density) of the conductive yarns 2a for energization By appropriately setting the value, a desired heating amount may be exhibited depending on the application. In FIG. 1, as an example, two conductive yarns 2a for energization and two unused conductive yarns 2b are alternately arranged.

  Both ends of the conductive yarn 2a for energization extend outward from the fabric edge 1a of the conductive fabric 1 and are exposed without being covered by the non-conductive yarn. Furthermore, when the outer periphery of the energizing conductive yarn 2a is covered with a resin material or the like, the covering material is removed from the outer periphery of the extending portion 2a1, and the conductive material is exposed. The exposed extension 2a1 is connected to the conductive connection member 6 as will be described later.

  Both ends of the unused conductive yarn 2 b also extend outward from the fabric edge 1 a of the conductive fabric 1. However, the extended portion 2 b 1 is entirely covered with the insulating coating 3. That is, the extending portion 2b1 of the unused conductive yarn 2b is electrically insulated from the members other than the conductive fabric 1 and the neighboring conductive yarn 2a by the insulating coating 3.

  The insulating coating 3 is made of a non-conductive yarn melted and re-solidified. That is, a thin film of an insulating material such as a thermoplastic resin constituting the non-conductive yarn covers the surface of the extending portion 2b1 of the unused conductive yarn 2b. When the melted thermoplastic resin is solidified, a dense film-like structure is often formed. Therefore, when the non-conductive yarn is made of a thermoplastic resin, the formed insulating coating 3 is High electrical insulation. Therefore, if the insulating coating 3 covers the entire surface of the extended portion 2b1 of the unused conductive yarn 2b, a very thin thickness is sufficient.

In addition, the length from the fabric edge 1a of the extension part 2a1 of the conductive yarn 2a for energization and the extension part 2b1 of the non-use conductive thread 2b does not need to be the same, but if it is the same length, it will be described later. As described above, when performing the exposure of the extended portion 2a1 of the conductive yarn 2a for energization and the insulation of the extended portion 2b1 of the unused conductive yarn 2b by laser irradiation, it is not necessary to go through a process of changing the lengths thereof. It can be easily manufactured.

  In FIG. 1, no other conductive cloth or the like is connected to the tip of the extending portion 2a1 of the conductive yarn 2a for energization, but a piece of fabric other than the conductive fabric 1 connects the conductive yarn 2a for energization. It can also be set as the state connected with the conductive fabric 1 via. In such a state, the extended portions 2a1 of the conductive yarns 2a for energization maintain a relative position to each other and are kept straight and the insulating coating 3 is applied to the end portions of the unused conductive yarns 2b. Workability at the time of forming or connecting the connecting member 6 by sewing or the like is improved.

  FIG. 2 shows a state where the connecting member 6 is attached to the conductive yarn 2a for energization of the conductive fabric 1 of FIG. The connection member 6 is a sheet member in which a conductive surface 6a having conductivity is formed on at least one surface. Examples of the conductive sheet member include a member in which a conductive material (for example, copper) is formed in a sheet shape, and a conductive fabric including a thread formed of a conductive material. The connection member 6 has a substantially U-shaped cross section so as to sandwich the extended portion 2a1 of the conductive yarn 2a for energization with the conductive surface 6a inside, and is sewn or the like. It is attached to the edge 1a. The connecting member 6 is connected to a power source via an electric wire 7.

  FIG. 2B shows a cross-sectional view of the position where the conductive yarn 2a for energization is arranged. The extending portion 2a1 is wrapped by the connecting member 6 and is in contact with the conductive surface 6a of the connecting member 6. Thereby, conduction | electrical_connection is formed between the electrically conductive thread 2a and the connection member 6, and the conductive fabric 1 is heated by energizing the electrically conductive thread 2a. In addition, in FIG.2 (b), although the extension part 2a1 is extended linearly, you may be wrapped in the connection member 6 in the state bent in the middle part.

  On the other hand, FIG. 2C shows a cross-sectional view of the position where the unused conductive yarn 2b is arranged. Since the connecting member 6 is a long and thin sheet extending over the ends of the plurality of conductive yarns 2, the entire fabric edge 1 a of the conductive fabric 1 including the extending portion 2 b 1 of the unused conductive yarn 2 b is wrapped. However, the extended portion 2b1 of the unused conductive yarn 2b is covered with the insulating coating 3 and electrically insulated from the surroundings. Therefore, no continuity is formed between the unused conductive yarn 2b, the connecting member 6 and the energizing conductive yarn 2a, and even if a current is supplied from the power source to the connecting member 6 and the energizing conductive yarn 2a is energized. The unused conductive yarn 2b is not energized.

  When the connecting member 6 and the conductive fabric 1 are deformed, for example, bent, the extending portion 2b1 of the unused conductive yarn 2b and the extending portion 2a1 of the connecting member 6 and the adjacent conductive yarn 2a for energization are physically connected. Even if they are in contact with each other, the extension 2b1 of the unused conductive yarn 2b is covered with the insulating coating 3, so that no electrical connection is formed at those physical contact points. . When the conductive fabric 1 is used as a seat heater for a vehicle seat, the conductive fabric 1 is subjected to deformation such as bending as the passengers get on and off and move in a seated state. It is considered that physical contact between the extended portion 2b1 of the used conductive yarn 2b and the extended portion 2a1 of the connecting member 6 or the conductive yarn 2a for energization frequently occurs, and the unused conductive yarn 2b as in this embodiment. It is particularly effective to provide the insulating coating 3 on the extended portion 2b1.

  Next, an example of a method for manufacturing the conductive fabric 1 according to the first embodiment of the present invention and a method for connecting the connection member 6 to the manufactured conductive fabric 1 will be described with reference to FIG. . As an outline of the manufacturing process, first, as shown in FIG. 3A, a rectangular original fabric 1 'is prepared, and a mark for identifying the unused conductive yarn 2b is formed as necessary. Next, by performing laser irradiation as shown in FIG. 3B, exposure of the conductive material of the extended portion 2a1 of the conductive yarn 2a for energization, formation of the fabric edge 1a, and extended portion 2b1 of the unused conductive yarn 2b are performed. The insulating coating 3 is formed on the substrate. And the connection member 6 is arrange | positioned like FIG.3 (c), and the connection member 6 is finally fixed to the electroconductive cloth 1 like FIG.3 (d). Details of each step will be described below.

First, as shown in FIG. 3A, a rectangular original fabric 1 'is prepared. What is necessary is just to obtain the original fabric 1 'by cutting out from a long fabric containing the conductive yarn 2 and the non-conductive yarn. At this time, the length in the direction parallel to the arrangement of the conductive yarns 2 in the raw fabric 1 ′ is set so that the length of the conductive fabric 1 is equal to the length of the extension portions 2b1 of the unused conductive yarns 2b and the conductive yarns 2a. It is set as the length which added the length of the longer one among the protrusion parts 2a1. In the present embodiment, it is assumed that the lengths of the extending portions 2a1 and 2b1 are equal. The original fabric 1 'may be cut out using a blade such as a scissors or a cutter or laser light.

  In the state of the original fabric 1 ', it is determined which conductive yarn 2 is the non-use conductive yarn 2b and which conductive yarn 2 is the conductive yarn 2a for energization. Furthermore, if a means that requires a mark for detecting the conductive yarn 2 such as a camera is used as the unused conductive yarn detection means described later, the position of the end of the conductive yarn 2 as the unused conductive yarn 2b A mark 4 is formed on the surface. As a means for forming the mark 4, for example, when the conductive fabric 1 is formed by weaving or knitting, a yarn (warp or weft) having a color different from that of the non-conductive yarn constituting the conductive fabric 1 is set at a predetermined position. Can be woven or knitted. Alternatively, the mark 4 may be formed at a predetermined position from above the raw fabric 1 ′ with a thread or ink having a color different from that of the non-conductive thread constituting the fabric 1. In any case, the mark 4 does not hinder the melting of the non-conductive yarn arranged in the vicinity thereof by the laser beam, and the mark 4 itself is also melted or burned off, which affects the design of the conductive fabric 1 after completion. It is necessary to select the thread and ink to be used so as not to occur. In this sense, it is preferable to use a thread or ink made of an organic substance that is easily melted or burned.

  Next, by laser irradiation, the conductive member of the extended portion 2a1 of the conductive yarn 2a for energization is exposed and the fabric edge 1a is formed, and the insulating coating 3 is formed on the extended portion 2b1 of the unused conductive yarn 2b, The conductive fabric 1 is brought into the state shown in FIG. By irradiating the non-conductive yarn with laser light, the irradiated portion can be heated, and the non-conductive yarn can be melted, evaporated, or burned. Using this, both removal of the non-conductive yarn and formation of the coating are performed.

  Since it is necessary to quickly remove the melted and evaporated non-conductive yarn from the place where the non-conductive yarn should be removed, laser irradiation is performed with an assist gas made of an inert gas such as nitrogen or helium at a high pressure. You must be able to do it under the specified conditions. As a laser beam to be used, it is necessary to select a laser beam having a wavelength and an intensity capable of heating the irradiation region above the melting point of the nonconductive yarn. A carbon dioxide laser capable of outputting infrared light that is absorbed with high efficiency by an organic substance such as a thermoplastic resin and converted into heat with high intensity over a wide wavelength region is suitable.

  About the extension part 2a1 of the conductive yarn 2a for energization, it is necessary to remove the surrounding nonconductive yarn in order to expose the conductive material. In addition, in the region where the conductive yarn 2 is not disposed and only the non-conductive yarn is formed, the non-conductive yarn in the region between the raw fabric edge 1a ′ and the fabric edge 1a is removed to form the fabric edge 1a. There is a need. About these places, after adjusting the intensity | strength of a laser beam to the range which melts | dissolves or burns a nonelectroconductive thread | yarn, the conductive material which comprises the conductive thread | yarn 2 does not melt | dissolve and burn, laser beam irradiation is performed. At this time, the flow rate of the assist gas needs to be adjusted so that the substance generated by melting or burning the non-conductive yarn is removed from the site before re-solidification or a new chemical reaction occurs.

  If laser irradiation is performed on a predetermined region under such conditions, the non-conductive yarn melts, evaporates or burns by laser irradiation, and is quickly taken away from the portion. The non-conductive yarn in the region where the yarn 2 is not disposed can be removed. If the outer periphery of the conductive yarn 2a for energization is coated with a resin material or the like, if the intensity of the laser beam is adjusted to a range that can also remove this coating, this coating will be removed together with the non-conductive yarn. The conductive material that constitutes the conductive yarn 2a is exposed.

  On the other hand, it is necessary to form the insulating coating 3 for the extended portion 2b1 of the unused conductive yarn 2b. That is, it is necessary to melt the non-conductive yarn surrounding the extending portion 2b1 of the unused conductive yarn 2b and solidify the constituent material of the molten non-conductive yarn in a state of covering the extended portion 2b1 of the unused conductive yarn 2b. is there. Therefore, the non-conductive yarn is melted but not evaporated or burned, and the melted non-conductive yarn constituent material is not carried away by the assist gas before the unused conductive yarn 2b is coated and solidified. Laser irradiation may be performed under conditions.

  More specifically, the condition in removing the non-conductive yarn in the region around the conductive yarn 2a for energization and the region where the conductive yarn 2 is not disposed (hereinafter may be referred to as non-conductive yarn removal condition). However, laser light may be irradiated at a low intensity to prevent evaporation and combustion of the non-conductive yarn and to allow melting to proceed under mild conditions. However, it is necessary to secure a laser beam intensity sufficient to melt a necessary amount of non-conductive yarn. Or, the flow rate of the assist gas is weakened or stopped more than in the non-conductive yarn removal condition, and the melted non-conductive yarn constituent material is removed before it covers the surface of the extension portion 2b1 of the unused conductive yarn 2b and solidifies. You just don't have to. Alternatively, appropriate conditions may be selected using a combination of low intensity laser light and low assist gas flow (hereinafter, these conditions may be referred to as insulating coating formation conditions).

  By doing so, the non-conductive yarn surrounding the unused conductive yarn 2b is melted, and the constituent material of the melted non-conductive yarn flows to cover the extended portion 2b1 of the unused conductive yarn 2b without a gap. When the irradiation of the laser beam at that position is stopped, the heated portion is allowed to cool and the constituent material of the melted non-conductive yarn is re-solidified. The constituent material of the non-conductive yarn that has been re-solidified by covering the surface of the extended portion 2 b 1 of the unused conductive yarn 2 b becomes the insulating coating 3.

  As described above, the step of removing the non-conductive yarn in the region around the extended portion 2a1 of the conductive yarn 2a for energization and the region where the conductive yarn 2 is not disposed, and the surface of the extended portion 2b1 of the unused conductive yarn 2b The step of forming the insulating coating 3 can be performed by simply changing the laser irradiation condition and / or the assist gas injection condition using the same laser irradiation apparatus and assist gas injection apparatus. Therefore, laser irradiation and assist gas injection are performed while scanning the position of the conductive fabric 1 and / or the position of the laser beam emitting portion, and the non-conductive yarn removal condition or the insulating coating formation condition is selected according to the irradiation position. Thus, the non-conductive yarn can be removed and the insulating coating 3 can be continuously formed. In order to make the conditions of laser irradiation and assist gas injection constant even if the irradiation position changes, it is more preferable to scan the position of the conductive fabric 1 than to scan the position of the laser beam emitting portion.

  When the conductive yarns 2a and the unused conductive yarns 2b are alternately arranged as in the conductive cloth 1 shown in FIG. 1, the unused conductive yarns are detected at the locations where the unused conductive yarns 2b are present. If the control system is constructed so that the conditions of the laser irradiation and the assist gas injection are automatically switched from the non-conductive yarn removal condition to the insulating coating formation condition at that location, the production of the conductive fabric 1 is performed. It becomes possible to carry out efficiently and accurately.

  As the unused conductive yarn detection means, for example, a camera can be used. As shown in FIG. 3A, a mark 4 is formed in advance on the end portion of the conductive yarn 2 to be the unused conductive yarn 2b using a thread or ink. And the digital camera provided with an image processing means is fixed in the immediate vicinity of the emission part of a laser beam, and the surface of the conductive cloth 1 to be scanned is continuously photographed with the digital camera. When the obtained image is processed on the spot by the image processing means and a color or shape peculiar to the mark 4 is detected, the laser intensity and / or the flow rate of the assist gas are set as the values of the insulating coating forming condition, and otherwise In such a case, these conditions may be kept at the non-conductive yarn removal conditions.

  As the unused conductive yarn detecting means, a capacitance type or electromagnetic induction type metal sensor may be used instead of the camera. In this case, it is not necessary to form the mark 4 on the original fabric 1 '. A metal sensor is attached with its relative position fixed to the laser emitting portion, and the number of conductive yarns 2 that pass when the conductive fabric 1 is scanned is measured. The conductive conductive yarn 2a and the non-conductive conductive yarn 2b may be defined in such a manner that the number of the conductive yarn 2a and the non-conductive conductive yarn 2b from the end portion 1b perpendicular to the fabric edge 1a of the conductive fabric 1 are changed. In the case of FIG. 3, the third and fourth conductive yarns 2 from the end portion 1b may be the unused conductive yarns 2b.

  When the conductive yarns 2 are accurately arranged at equal intervals, it is not necessary to detect the unused conductive yarns 2b one by one using the above-described unused conductive yarn detection means. If the location where one unused conductive yarn 2b exists is detected by the unused conductive yarn detection means, then the scanning length of the conductive fabric 1 is measured using an encoder or the like, and based on the interval between the conductive yarns 2 The location of the unused conductive yarn 2b can be defined.

  The removal of the non-conductive yarn in the region around the conductive yarn 2a for energization and the region where the conductive yarn 2 is not disposed over the entire area between the raw fabric edge 1a 'and the line serving as the fabric edge 1a of the conductive fabric 1 In addition, it is necessary to form the insulating coating 3. However, in order to increase the brightness of the laser beam and increase the temperature raising efficiency of the irradiation region, the laser beam is usually focused on a small spot. Therefore, it is necessary to scan the laser irradiation position not only in the direction parallel to the fabric edge 1a but also in the vertical direction, and perform laser irradiation all over this region while switching the conditions. The process of scanning the laser irradiation position in a line parallel to the fabric edge 1a and shifting the irradiation position in the direction perpendicular to the fabric edge 1a may be repeated or vice versa.

  3 (b), the extension part 2a1 of the conductive yarn 2a for energization is exposed and the extension part 2b1 of the non-use conductive thread 2b is insulatively coated as shown in FIG. As shown in c), the connecting member 6 is disposed along the fabric edge 1a. At this time, it is necessary to arrange the connection member 6 at a position where the conductive surface 6a of the connection member 6 is surely in contact with the extending portion 2a1 of the conductive yarn 2a for energization. Even if the extending portion 2b1 of the unused conductive yarn 2b is physically in contact with the conductive surface 6a of the connecting member 6, it is not in electrical contact with the conductive surface 6a due to the effect of the insulating coating 3. The positional relationship between the extending portion 2b1 of the unused conductive yarn 2b and the connecting member 6 need not be strictly determined.

  Finally, as shown in FIG. 3D, the connection member 6 may be fixed to the conductive fabric 1 by bending and sewing the connection member 6 so as to wrap the fabric edge 1 a of the conductive fabric 1.

  In this way, the insulating coating 3 is formed on the extended portion 2b1 of the unused conductive yarn 2b, and the extension portion 2a1 of the conductive yarn 2a for energization is exposed using the same laser irradiation device. Even when the conductive yarn 2a for use and the unused conductive yarn 2b are adjacent to each other, it is possible to easily ensure the conduction of the conductive yarn 2a for conduction and the insulation of the unused conductive yarn 2b.

  In the first embodiment of the present invention described above, the extending portion of the unused conductive yarn is covered with the constituent material of the non-conductive yarn that has been melted and re-solidified. However, even if the non-conductive yarn is not necessarily melted and then re-solidified, it is also possible to insulate the extension of the unused conductive yarn with the non-conductive yarn while maintaining the original fabric structure.

  FIG. 4 shows a conductive fabric according to the second embodiment in which an insulating coating is formed on the extension portion of the unused conductive yarn without melting the nonconductive yarn. The end portion of the conductive yarn 22a for energization of the conductive fabric 21 extends outward from the fabric edge 21a, and the conductive material is exposed. Here, the fabric edge 21a is defined as a fabric edge made of a non-conductive yarn in a region where the energizing conductive yarn 21a extends.

  On the other hand, the end portion of the unused conductive yarn 22b also extends outward from the fabric edge 21a, but the extended portion 22b1 is not exposed to the outside and is surrounded by an insulating coating 23. The insulating coating 23 is constituted by a fabric structure made of non-conductive yarn, and has the same structure as the fabric structure made of non-conductive yarn inside the fabric edge 21a. The extension portion 22b1 of the unused conductive yarn 22b does not contact the external member such as the connection member and the extension portion 22a1 of the neighboring conductive yarn 22a for energization, and is electrically insulated from them.

  In order to manufacture such a conductive fabric, most steps may be performed in the same manner as in the method for manufacturing a conductive fabric according to the first embodiment. However, when performing laser irradiation while changing the conditions of laser irradiation and assist gas injection in FIG. 3 (b), the laser intensity and / or assist gas of the non-use conductive yarn 2b becomes the extension portion 2b1. When the flow rate is lowered and the melted non-conductive yarn is coated and solidified by covering the extended portion 2b1 of the unused conductive yarn 2b, laser irradiation is performed at a very low intensity at the position where the insulating coating 23 is to be formed. Or stop so that the non-conductive yarn is not melted. Then, in this portion, the fabric structure composed of the non-conductive yarn is not changed, and the insulating coating 23 that insulates and protects the extended portion 22b1 of the unused conductive yarn 22b while maintaining the original structure. It becomes.

  According to the conductive fabric 1 according to the first embodiment, since the insulating coating 3 can be formed very thin, the configuration of the end of the unused conductive yarn is simplified. On the contrary, according to the conductive fabric 21 according to the second embodiment, the extension portion 2b1 of the unused conductive yarn 2b is protected by the insulating coating 23 even on the structural surface. Maintained. These embodiments may be selected depending on the type and use of the conductive fabric.

As mentioned above, although embodiment of this invention was described in detail, this invention is not limited to the said embodiment, A various change is possible in the range which does not deviate from the summary of this invention. For example, in the above-described embodiment, the conductive yarn for energization and the non-use conductive yarn are periodically arranged at equal intervals, but they may be arranged in any manner. For example, when used as a seat heater, if it is desired to change the amount of heating according to the part of the human body that comes into contact, a region where the density of the conductive yarn for energization is high and low may be provided at a certain position. Furthermore, in order to set the boundary of such an area | region reliably, you may form the area | region where the unused conductive yarn concentrated and provided in the boundary of an area | region. Finally, the conductive fabric does not need to be formed in a rectangular shape, and may be formed in a shape corresponding to various uses.

DESCRIPTION OF SYMBOLS 1 Conductive cloth 1a Fabric edge 2 Conductive thread 2a Conductive thread 2a1 Conductive thread extension part 2b Unused conductive thread 2b1 Unused conductive thread extension part 3 Insulation coating 4 Marking 6 Connection member 6a Conductive surface

Claims (3)

In a conductive fabric including a conductive yarn and a non-conductive yarn, and a non-conductive conductive yarn in which some of the conductive yarns are not energized, including a termination surface of the non-conductive conductive yarn, An end portion of the unused conductive yarn, which is a region occupying a part of the longitudinal direction of the unused conductive yarn , extends outward from an end edge of the conductive fabric, and the extended portion serves as the conductive fabric. A conductive fabric characterized in that it is covered with an insulating member made of a material derived from non-conductive yarn. The conductive fabric according to claim 1, wherein an end portion of the non-conductive conductive yarn is covered with a constituent material of the non-conductive yarn which has been melted and re-solidified. The conductive yarn includes a conductive yarn and a non-conductive yarn, and some of the conductive yarn is a conductive yarn for energization in which the conductive material at the end, which is a region including a terminal surface and occupies a part in the longitudinal direction, is exposed. The conductive yarn is an unused conductive yarn including an end surface, an end portion that occupies a part in the longitudinal direction extending outward from the edge of the conductive fabric, and the extending portion is insulated and coated. In the method for manufacturing a conductive fabric, the conductive yarn for energization is applied to the conductive fabric in a state in which ends of the conductive yarn for energization and the unused conductive yarn are surrounded by the non-conductive yarn of the conductive fabric. By irradiating a laser beam to the region made of the non-conductive yarn surrounding the end of the conductive wire under the assist gas injection, the non-conductive yarn surrounding the end of the conductive yarn for melting is removed by melting or burning, A first step of exposing a conductive material constituting the conductive yarn, and the non-use conductive yarn By irradiating the region of the non-conductive yarn surrounding the end portion with the laser beam in a state where the intensity of the laser beam and / or the flow rate of the assist gas is lower than in the first step, the end of the unused conductive yarn The non-conductive yarn surrounding the portion is melted, and the constituent material of the melted non-conductive yarn is re-solidified in a state of covering the end portion of the non-conductive conductive yarn, and the end of the non-conductive conductive yarn is the end of the conductive fabric. A method for producing a conductive fabric, comprising forming an insulating member covering a portion extending outward from an edge .

Images