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Heating yarn and woven or knitted fabric using this heating yarn




Title: Heating yarn and woven or knitted fabric using this heating yarn.
Abstract: A heating yarn includes an insulating yarn and a conductive yarn that is wound around the insulating yarn. The conductive yarn has an insulating core yarn and a plated layer (such as a copper plated layer) formed on a peripheral surface of the core yarn, and the core yarn is a high elasticity yarn (such as an aramid fiber) with an initial tensile resistance of 4.9 GPa or higher. Moreover, the heating yarn is woven in or knitted into the woven or knitted fabric as part of the constituent yarn. ...


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USPTO Applicaton #: #20120100386
Inventors: Yoshiteru Honma, Hideaki Kunisada


The Patent Description & Claims data below is from USPTO Patent Application 20120100386, Heating yarn and woven or knitted fabric using this heating yarn.

INCORPORATION BY REFERENCE

The disclosure of Japanese Patent Application No. 2010-235846 filed on Oct. 20, 2010 including the specification, drawings and abstract is incorporated herein by reference in its entirety.

BACKGROUND

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OF THE INVENTION

1. Field of the Invention

The invention relates to a heating yarn and a woven or knitted fabric that uses this heating yarn. More specifically, the invention relates to a heating yarn that uses a high elasticity yarn having a specified initial tensile resistance as a core yarn of a conductive yarn, such that when the heating yarn in which this conductive yarn is wound around the peripheral surface of an insulating yarn is flexed or when tensile stress is applied to the heating yarn or the like, the core yarn will not easily stretch or otherwise deform, so the plated layer formed on the peripheral surface of the core yarn, will not crack and the conductive yarn will not break. The invention also relates to a woven or knitted fabric that can be used in a variety of applications as a heater member, in which this heating yarn is woven or knitted in as part of the constituent yarn.

2. Description of Related Art

A variety of flat heating bodies have been used as heater members and the like for vehicle seats. One such known heating body is a heating seat in which heating wires and insulating wires are alternately arranged, and the insulating wires that are warp yarns are woven in with electrode wires (see Japanese Patent Application Publication No. 7-161456 (JP-A-7-161456), for example). In this heating seat, heating wires in which stainless steel resistance heating wires as the heating body are wound around insulating wires formed by synthetic fiber twisted yarns are used. Also, for a seat of a vehicle, particularly a seat of a passenger vehicle or the like, a seat that can warm an occupant during wintertime or the like by a heater member being adhered to the back surface of cover material is known. One example of a heater member used in this kind of a seat is a seat heater woven from a plurality of conductive warp yarns that generate heat when current passes through them, and a plurality of non-conductive weft yarns that are electrically insulated from the conductive warp yarns, in which the conductive warp yarns are arranged closer together on the side opposite a seat back than they are on the seat back side (see Japanese Patent Application Publication No. 2008-67850 (JP-A-2008-67850), for example).

However, in the heating seat described in JP-A-7-161456, stainless steel resistance heating wires are used as the heating body. Therefore, even if stress is distributed by the stainless steel resistance heating wires being wound around the insulating wires, when the heating seat is flexed or when tensile stress is applied to the heating seat or the like, the heating body will also flex and stretch, and as a result, the stainless steel resistance heating wires, i.e., the heating body, may break. Furthermore, when a heating body that is more flexible than the stainless steel resistance heating wires is used, e.g., when a heating body in which a plated layer is formed on the peripheral surface of a polyester fiber or the like is used, the heating body may stretch and the plated layer may crack and peel away when tensile stress or the like is applied. Also, when the heating seat is used in a vehicle seat, as is the case with the seat heater described in JP-A-2008-67850, a fairly large amount of stress is applied to the heater member when an occupant ingresses and egresses. Therefore, a heater member that is more resistant to breaking or the like must be used.

SUMMARY

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OF THE INVENTION

The invention thus provides a heating yarn that uses a high elasticity yarn having a specified initial tensile resistance as a core yarn of a conductive yarn, such that when a heating yarn is flexed or when tensile stress is applied to the heating yarn or the like, the core yarn will not easily stretch, so a plated layer formed on the peripheral surface of the core yarn will not crack and the conductive yarn will not break. The invention also provides a woven or knitted fabric that is useful as a heater member, in which this heating yarn is woven or knitted in as part of the constituent yarn.

A first aspect of the invention relates to a heating yarn that includes an insulating yarn and a conductive yarn that is wound around the insulating yarn. The conductive yarn has an insulating core yarn and a plated layer formed on a peripheral surface of the core yarn, and the core yarn is a high elasticity yarn with an initial tensile resistance of 4.9 GPa or higher. In this aspect, a resin coating layer may be formed on a surface of the plated layer. Also, the plated layer may be a copper plated layer, and a tin plated layer or a nickel plated layer may be formed on a surface of the copper plated layer. A second aspect of the invention relates to a woven or knitted fabric into which the heating yarn according to the first aspect is woven or knitted.

With the heating yarn according to the first aspect of the invention, a high elasticity yarn that has a specific initial tensile resistance is used as the core yarn of the conductive yarn. The conductive yarn has a high flex resistance and is strong in the length direction. Therefore, when the heating yarn in which this conductive yarn is wound around the insulating yarn is flexed, the core yarn of the conductive yarn will not stretch, so the plated layer formed on the peripheral surface thereof will not crack, and when tensile stress is applied to the heating yarn, the conductive yarn will not break. Also, when the resin coating layer is formed on the surface of the plated layer, the plated layer is protected by the resin coating layer, so oxidation degradation of the plated layer, and a change in the resistance value due to that oxidation degradation, are suppressed, and wear of the plated layer is also suppressed. Moreover, when the plated layer is a copper plated layer, and a tin plated layer or a nickel plated layer is formed on the surface of the copper plated layer, the copper plated layer will be covered, and thus protected, by the plated layer formed of tin or nickel that does not oxidize as easily as copper and has good wear resistance. Therefore, oxidation degradation of the copper plated layer, and a change in the resistance value due to that oxidation degradation, can be suppressed, and wear of the copper plated layer can also be suppressed. With the woven or knitted fabric of the second example embodiment of the invention, the heating yarn of the first aspect is woven or knitted in as part of the constituent yarn, so when the woven or knitted fabric deforms due to stress being applied or the like, the plated layer of the conductive yarn will not crack and the conductive yarn will not break or the like. Accordingly, the woven or knitted fabric is able to maintain good heat generating performance when used as a heater member of a passenger vehicle or the like, for example.

BRIEF DESCRIPTION OF THE DRAWINGS

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Features, advantages, and technical and industrial significance of exemplary embodiments of the invention will be described below with reference to the accompanying drawings, in which like numerals denote like elements, and wherein:

FIG. 1 is a view showing a frame format of a cross-section of a conductive yarn that has a core yarn and a plated layer formed on the peripheral surface of the core yarn, and that is used wound around an insulating yarn;

FIG. 2 is a view showing a frame format of a cross-section of a conductive yarn that has a core yarn, a plated layer formed on the peripheral surface of the core yarn, and a resin coating layer or a plated layer formed on the surface of that plated layer, and that is used wound around an insulating yarn;

FIG. 3A is a side view of a heating yarn in which a conductive yarn is wound in an S direction around an insulating yarn;

FIG. 3B is a side view of a heating yarn in which the conductive yarn is wound in a Z direction around the insulating yarn;

FIG. 4 is a side view of a heating yarn in which a conductive yarn is wound in both the S and Z directions around an insulating yarn;

FIG. 5 is a front view showing a frame format of a knitted fabric into which a heating yarn of an example embodiment of the invention is knitted as part of a constituent yarn;

FIG. 6 is a perspective view showing a frame format of a vehicle seat in which a woven or knitted fabric of an example embodiment of the invention in arranged as a heater member on a back surface of cover material.

DETAILED DESCRIPTION

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OF EMBODIMENTS

Hereinafter, the invention will be described in detail with reference to FIGS. 1 to 6. The description here is illustrative in purpose and is simply intended to describe example embodiments of the invention. The purpose is to provide description of the principle and conceptual characteristics of the invention in the most effective and comprehensible manner possible. Regarding this, there is no intent to give any structural detail of the invention beyond what is necessary to gain a fundamental understanding of the invention. The way in which various modes of the invention are actually embodied is made evident to one skilled in the art by the description together with the drawings.

A heating yarn 10 of one example embodiment of the invention includes an insulating yarn 101 and a conductive yarn 1 that is wound around this insulating yarn 101. The conductive yarn 1 has an insulating core yarn 11 and a plated layer 12 formed on the peripheral surface of the insulating core yarn 11. A high elasticity yarn with an initial tensile resistance of 4.9 GPa or higher is used as the insulating core yarn 11 (see FIGS. 1, 3, and 4).

Examples of the insulating yarn 101 include a yarn made of a synthetic fiber made using a synthetic resin such as polyester or polyamide, a natural fiber of a plant system or an animal system, a regenerated fiber such as rayon, or a semi-synthetic fiber such as acetate, and the like. The insulating yarn is preferably yarn that is made using a synthetic fiber, and more preferably, yarn that is made using a polyester fiber.

Only one of these types of insulating yarn may be used, or two or more types may be used together. Also, filament yarn is preferably used as the insulating yarn. Either multifilament or monofilament may be used, though multifilament is more preferable. Furthermore, the fineness of the insulating yarn is preferably 10 to 2000 dtex, and more particularly 84 to 550 dtex. Also, the insulating yarn may be a textured yarn that has been false twisted, for example. These insulating yarns normally have an insulation property with a specific resistance exceeding 108Ω×cm.

The conductive yarn 1 has the insulating core yarn 11 and the plated layer 12 that is formed on the peripheral surface of the insulating core yarn 11. The heating yarn 10 is formed by this conductive yarn 1 being wound around the insulating yarn 101 (see FIGS. 3 and 4). The heating yarn 10 may be a single covering yarn in which the conductive yarn 1 covers the outer periphery of the insulating yarn 101 in the S direction or the Z direction, or a double covering yarn in which the conductive yarn 1 covers the outer periphery of the insulating yarn 101 in both the S and the Z directions. Also, the actual number of twists is not particularly limited, but with a single covering yarn, as well as with a double covering yarn, the actual number of twists is preferably 50 to 1000 T/m, and more preferably, 100 to 500 T/m. If the actual number of twists is within this range, the heating yarn 10 will be able to heat sufficiently for practical use.

A high elasticity yarn with an initial tensile resistance of 4.9 GPa or higher may be used as the insulating core yarn 11. The high elasticity yarn is strong and does not stretch much, so the core yarn 11 will not easily stretch or otherwise deform when the heating yarn 10 is flexed or tensile stress is applied to the heating yarn 10. As a result, the plated layer 12 will not crack and the conductive yarn 1 will not break.

Yarn such as an industrial polyester yarn or a high-strength polyethylene yarn may also be used as the high elasticity yarn. More preferably, however, a yarn that uses a variety of types of fiber that is very strong, has a high melting point, and is flame retardant, such as a para-type aramid fiber, a meta-type aramid fiber, a polyarylate fiber, a poly-para-phenylene benzobis oxazole fiber, a polyphenylene sulfide fiber, a polyether ether ketone fiber, a polyimide fiber, or a PAN-based carbon fiber, is used. The initial tensile resistance of the high elasticity yarn is 4.9 GPa or higher, and preferably 4.9 to 600 GPa, and more preferably 54 to 280 GPa. The initial tensile resistance of the high elasticity yarn is a value measured based on JIS L10138.10.

Specific examples of a more preferable high elasticity yarn is a high elasticity yarn made using a para-type aramid fiber with an initial tensile resistance of 54 to 199 GPa, such as Kevlar (Trademark) by DuPont or Technola (Trademark) by Teijin, a high elasticity yarn made using a polyarylate fiber with an initial tensile resistance of 74 to 104 GPa, such as Vectran (Trademark) by Kuraray, and a high elasticity yarn made using a poly-para-phenylene benzobis oxazole fiber with an initial tensile resistance of 180 to 280 GPa, such as Zylon (Trademark) by Toyobo.

The high elasticity yarn is a filament yarn, which may be multifilament or monofilament, but multifilament is preferable. Also, the single yarn fineness is not particularly limited, but is preferably 0.1 to 30 dtex, and more preferably 1 to 20 dtex. A single yarn fineness of 0.1 to 30 dtex enables the conductive yarn 1 to be easily wound around the insulating yarn 101.

The plated layer 12 is formed on the peripheral surface of the high elasticity yarn that is the insulating core yarn 11, thereby forming the conductive yarn 1 (see FIG. 1). This plated layer 12 is formed by a non-electrolytic plating method, and preferably uses a metal with good conductivity, such as copper, silver, or nickel. A plated layer that uses copper, which is inexpensive, and a plated layer that uses nickel, which has good corrosion resistance, are even more preferable. The thickness of this plated layer 12 may be set according to the type of metal, and the use of the woven or knitted fabric or the like. For example, the thickness may be 0.1 to 10 μm, and more preferably 0.3 to 5 μm. Also, when the plated layer 12 is a copper plated layer, in particular, there may be oxidation degradation, and copper is a metal with low hardness, so it is not necessarily sufficiently wear resistant. Therefore, when a copper plated layer in particular is used, a covering layer 13 that is both oxidation resistant and wear resistant is preferably formed on the surface of the copper plated layer to protect it (see FIG. 2).




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stats Patent Info
Application #
US 20120100386 A1
Publish Date
04/26/2012
Document #
File Date
12/31/1969
USPTO Class
Other USPTO Classes
International Class
/
Drawings
0




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Stock Material Or Miscellaneous Articles   All Metal Or With Adjacent Metals   Helical Or With Helical Component  

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20120426|20120100386|heating yarn and woven or knitted fabric using this heating yarn|A heating yarn includes an insulating yarn and a conductive yarn that is wound around the insulating yarn. The conductive yarn has an insulating core yarn and a plated layer (such as a copper plated layer) formed on a peripheral surface of the core yarn, and the core yarn is |Toyota-Boshoku-Kabushiki-Kaisha
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