JPS6321114Y2 - - Google Patents

Description

[Detailed Description of the Invention] The present invention relates to a knitted fabric used as a base fabric for a surface heating element.

In recent years, awareness of surface heating elements has improved, and together with the increasing demand for them, several proposals have been made as base fabrics for surface heating elements. For example, conductive electric wires such as metal wires or carbon fibers are inserted into some of the warp or weft threads of the fabric, and electricity is applied to the wires to create a heat-generating base fabric.

However, in order to be able to be used as a base fabric for a surface heating element, the electrical conductor wires as described above must be inserted continuously over the entire surface of the base fabric without being cut at the ears or the ends of the base fabric. It is possible to conduct electricity from the positive side of the conductor to the negative side.
This is an essential condition, and in this point the conductive fibers must be continuous.
Regardless of cutting or orientation. This is completely different from the case where the purpose is to impart antistatic properties, where the purpose can be achieved by mixing a small amount of non-oriented material into the base fabric.

Moreover, since the electric conductor wire used in the surface heating base fabric heats the entire surface of the base fabric to an appropriate temperature by energizing it, it is generally not possible to insert a single thread of ultra-fine fibers into the conductor wire. Unlike regular threads, they are made by twisting multiple thin metal wires together, or by coating them with insulation, or by relatively thick threads made from carbon fiber. In order to obtain the base fabric, a thick conducting wire with a diameter of 0.2 m/m to 4 m/m is generally required. In addition, in order to obtain the heat generation temperature as designed for the heating base fabric, it is required that the length of the electrical conductor inserted within the unit area of the base fabric is exactly as designed. It is necessary that it is driven into the base fabric in a straight state without bending.

However, in the fabric structure in which warp and warp yarns are interlaced according to the above proposal, conductive wires that require continuity over the entire surface of the base fabric cannot be used as warp yarns, and must necessarily be inserted as weft yarns. However,
In any of the normal throw-shuttle looms, rapier looms, or gripper looms used in this case, it is difficult to insert one thick and rigid electrical conductor without cutting it. In the case of looms, it is almost impossible to wind the thick and rigid conductor wire around the weft tube, and loops occur in the fabric due to the untwisting that occurs when it is untwisted from the weft tube. However, it is becoming increasingly difficult to type correctly.

In addition, even in the case of rapier looms and gripper looms, in order to drive a single conductor in the weft direction, the conductor must be cut at both ears, which naturally impairs the continuity of the conductor, which ultimately results in the fabric being woven. A satisfactory heat generating base fabric cannot be obtained with this structure.

Therefore, in order to utilize knitted fabric instead of the above-mentioned woven structure, attempts were made to use warp knitting machines with multiple numbers of reeds and weft knitting machines, and metal thread staple blend yarns were inserted into the warp knitted fabric. 1988-89468 and 1989-89468,
It was proposed in Publication No. 49-127573, Publication Utility Model Publication No. 40400/1982, and Publication No. 43637/1983.

However, even when using these knitted fabrics, when knitting using a normal knitting machine, it is necessary to use a weft knitting machine in order to obtain continuity of conductors, just as in the case of textiles. However, with a structure composed of loops of weft knitting yarn, it is natural that the conducting wire cannot be expected to be inserted linearly, and due to the nature of the thick and rigid conducting wire, there are limitations in its handling. become.

On the other hand, even when using a warp knitting machine, the generally used knitting machine for knitting warp knitted fabrics as described in the above-mentioned Japanese Utility Model Application Publication No. 1989-89468 requires complicated insertion of electric conductors by weaving, which reduces production efficiency. A decrease in the conductive wire is unavoidable, and even when the wire is inserted, a thick electrical conductor is exposed on the knitted surface, causing problems in appearance.

In view of the above-mentioned actual situation, the present invention overcomes each of these difficulties and improves the thickness of each yarn used, the arrangement of the ground weft, the integration of the electrical conductor and the ground weft by warp knitting yarn, and the insertion mode of the electrical conductor. The purpose is to improve the conventional base fabric for surface heating elements by combining ground weft and warp knitting yarns that have electrical insulation properties and conductive filaments that have electrical conductivity, such as for heating purposes. Consisting of heater wires, the heating wires are knitted by warp knitting yarns arranged in parallel in the warp direction with parallel weft yarns at desired intervals in the weft direction by chain stitch or tricot stitch, In particular, the heat generating heater wire is characterized by a structure in which it is not cut at all at both ends, but is continuously knitted in a straight line over the entire width, and is protected by thick ground knitting yarn.

Hereinafter, specific embodiments of the present invention will be further described in detail based on the accompanying drawings.

FIG. 1 is a schematic plan view showing an example of the knitted fabric of the present invention;
FIG. 2 is an enlarged view of the same part.

In these figures, 1 is ground weft, 2 is warp knitting yarn,
3 is a conductive filament having electrical conductivity, and the ground weft 1
forms a base part by forming ears at both ends over a required width of the knitted fabric and bending them in a zigzag pattern, and the conductive filaments 3 are arranged in parallel in the base part. They are arranged in parallel to the ground weft 1 at appropriate intervals across the weft direction width of the ground weft 1, and are continuously knitted in a straight line forming ears on both sides without being cut. The warp knitting yarns 2 are knitted by forming chain stitches in the warp direction at appropriate intervals in the weft direction width of the knitted surface consisting of a mixed parallel arrangement of ground weft yarns 1 and conductive filaments 3. The ground weft 1 and the conductive filaments 3 are inserted into the stitches to form an integral structure as a knitted fabric for a surface heating element.

Here, the ground weft yarn 1 and the warp knitting yarn 2 in the above structure need to be yarns having electrical insulation properties, and are usually made of any fiber such as natural fiber, recycled cellulose fiber, inorganic fiber, or synthetic fiber. The selected fibers do not necessarily have to be the same, and in particular, the thickness of the ground weft 1 can be changed at any time depending on the thickness of the conductive filaments 3 to be used. It is preferable to use a yarn thicker than the warp knitting yarn 2 in order to reduce the sense of unevenness caused by the sensor conducting wire 4, which will be described later. And these ground weft 1,
Any of the warp knitting yarns 2 can be used as a plied yarn by aligning or twisting one or more warp yarns, and the weaving density is not particularly limited either.

On the other hand, the conductive filament 3 is made of a metal wire or carbon fiber having a suitable electrical conductivity since it constitutes a heater wire for generating heat, and these wires are used as bare wires or insulated wires. As mentioned above, it is preferable that the thickness of the filaments 3 to be used match the thickness of the base weft 1 so as not to impair the appearance of the base fabric. In addition, if the insertion interval of the conductive filaments 3 into the ground where the ground wefts 1 are arranged in parallel is too wide, it will reduce the heat retention due to the surface heat generation, while if it is too narrow, it will be wasteful. Since heat retention is to be provided, it is desirable to set an appropriate interval according to the electrical resistance of the conductive filament and the desired heat generation temperature, and the interval is usually 10 to 15 mm. However, depending on the heat generation situation, it is quite possible to have a diameter of about 5 mm or more than 15 mm.

Further, as shown in FIG. 2, the warp knitting yarn 2 is most commonly chain stitched, but there is no problem in replacing it with other tricot stitches.

The embodiments shown in FIGS. 1 and 2 described above are basic aspects of the present invention, and various preferable configurations can be added to the embodiments of the present invention.

For example, FIGS. 3 and 4 show various aspects of modified embodiments of the present invention. In FIG. In addition to the conductive wire 3, a temperature control sensor 4 having electrical conductivity made of a wire similar to the conductive wire described above is added, and the structure is such that two types of conductive wires 3 and 4 are woven together. In this case, although not shown, a known thermostat is combined to automatically adjust the temperature of the surface heating element.

On the other hand, in FIG. 4, warp yarns 5 having electrical insulation properties are simultaneously inserted and knitted in the warp direction between the stitches of the warp knitting yarns 2, similar to the ground weft yarns 1 and the warp knitting yarns 2, and the warp yarns 5 are knitted in the warp direction of the base fabric itself. Consideration has been given to stabilization to reduce dimensional changes in direction.

Either one of these configurations may be added, or both configurations may be added together.

Next, the knitted fabric having the above-mentioned structure can be easily produced by using a weft insertion warp knitting machine, and with this machine, it is possible to knit and produce conductive filaments like a shuttle loom. There is no need to wind the conductive wires into a weft tube in advance, and there is no need to cut the conductive wires at the ears as in a rapier loom. It can be inserted in the same direction and knitted at the same time, and can be rationally produced as a base fabric for heating elements.

In short, the above-mentioned knitted fabric in the present invention is
It is necessary for all types of conductive filaments to be knitted linearly and continuously in the weft direction at desired intervals without being cut at the selvedges. After the continuous structure is knitted,
There is no problem even if it is cut, which is naturally included in the present invention.

The knitted fabric for a surface heating element of the present invention is constructed as described above,
When using the knitted fabric, cut it in the width direction to the desired dimensions, attach the socket and other necessary parts to the space provided in advance, and use it as is or after coating the front and back sides of the knitted fabric with an appropriate resin. By energizing a heating wire (conductive wire), it becomes a heating element, and it is placed under a carpet, mat, blanket, futon, sheet, bed pad, etc., or it is laminated or adhered to them. It can be used as a heating product.

Furthermore, by forming the knitted fabric into a narrow width, storing it in a narrow tightening band such as a belt, and using it in combination, it can be used in a wide range of applications such as medical use as a local warming device for the human body.

As described in detail above, the present invention is composed of ground weft and warp knitting yarns having electrical insulation properties and conductive filaments having electrical conductivity, and the conductive filaments are spread over the entire surface without being cut at the edges. Since the warp knitting yarn is knitted continuously and linearly over the entire width in the weft direction at desired intervals, it is easy to manufacture unlike conventional knitted fabrics, and the conductive filaments can be cut. It is possible to knit continuously without
Although it is made of knitted fabric, it is inserted in a straight line to the ground weft, making it easy to knit at the same time, and there is no need to separately insert it into the knitted fabric, unlike knitting that consists of stitches. The conductive filament yarn is convenient to handle and can be inserted in a straight line as a base fabric for a surface heating element, which has a remarkable effect on improving production efficiency.

In addition, in the knitted fabric of the present invention, the conductive filaments are inserted into the stitches of the warp knitting yarn together with the ground weft, and their position is stably maintained and their shape is less likely to be deformed. The thick yarn reduces the unevenness on the surface of the knitted fabric due to the inclusion of conductive filaments, and the appearance is also very good.

Furthermore, since the conductive filaments are inserted in a straight line over the entire width in the weft direction, the thickness of the ground weft yarn and the thinness of the warp knitting yarn make it easy to bend along the weft direction as a crease line, making it easy to handle. The knitted fabric of the present invention has the characteristics of being extremely convenient and maintains excellent performance as a knitted fabric for surface heating elements, and its practical application is highly anticipated in the future.

[Brief explanation of the drawing]

FIG. 1 is a schematic plan explanatory diagram showing one example of the present invention;
FIG. 2 is an enlarged view of the same part, and FIGS. 3 and 4 are schematic plan explanatory views showing various modified embodiments of the present invention. 1... Ground weft, 2... Warp knitting yarn, 3... Conductive filament, 4... Sensor, 5... Warp.

Claims (1)

[Claims for Utility Model Registration] 1. Includes ground weft and warp knitting yarns of different thicknesses that have electrical insulation properties, as well as conductive filaments that have electrical conductivity, where the ground weft is relatively thicker than the warp knitting threads. The ground portion is formed by bending and paralleling in a zigzag shape with ears at both ends over the width of In a straight line parallel to the weft,
And, the warp knitting yarn is knitted continuously without being cut with ears on both ends thereof, and the warp knitting yarn is appropriately spaced between the ground weft yarn and the conductive filament width in the weft direction. for a surface heating element, characterized in that the base weft and the conductive filament are inserted and knitted in the warp stitches in a longitudinal direction perpendicular to the weft direction to form a warp knit stitch. Knitted fabric. 2. The surface according to claim 1 of the utility model registration claim, in which warp threads are inserted at appropriate intervals in parallel to the warp knitting stitches to prevent dimensional changes, perpendicular to the parallel direction of the ground weft threads and conductive filaments arranged in parallel. Knitted fabric for heating elements. 3. A utility model registration request in which temperature control sensors consisting of conductive filaments are further woven at appropriate intervals between the parallel ground weft and conductive filaments with ears formed at both ends. A knitted fabric for a surface heating element according to item 1 or 2.