U.S. patent application number 13/274658 was filed with the patent office on 2012-04-26 for heating yarn and woven or knitted fabric using this heating yarn.
This patent application is currently assigned to TOYOTA BOSHOKU KABUSHIKI KAISHA. Invention is credited to Yoshiteru HONMA, Hideaki KUNISADA.
Application Number | 20120100386 13/274658 |
Document ID | / |
Family ID | 45973258 |
Filed Date | 2012-04-26 |
United States Patent
Application |
20120100386 |
Kind Code |
A1 |
HONMA; Yoshiteru ; et
al. |
April 26, 2012 |
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.
Inventors: |
HONMA; Yoshiteru;
(Toyota-shi, JP) ; KUNISADA; Hideaki; (Komaki-shi,
JP) |
Assignee: |
TOYOTA BOSHOKU KABUSHIKI
KAISHA
Aichi-ken
JP
|
Family ID: |
45973258 |
Appl. No.: |
13/274658 |
Filed: |
October 17, 2011 |
Current U.S.
Class: |
428/592 ;
428/377; 442/184; 442/306 |
Current CPC
Class: |
D02G 3/441 20130101;
B60N 2/5685 20130101; D03D 15/00 20130101; D03D 15/47 20210101;
D10B 2401/16 20130101; D04B 1/14 20130101; Y10T 428/12333 20150115;
Y10T 428/2936 20150115; D02G 3/32 20130101; Y10T 442/413 20150401;
B60N 2/58 20130101; Y10T 442/3024 20150401 |
Class at
Publication: |
428/592 ;
428/377; 442/306; 442/184 |
International
Class: |
D02G 3/38 20060101
D02G003/38; D02G 3/12 20060101 D02G003/12; D03D 15/00 20060101
D03D015/00; D02G 3/32 20060101 D02G003/32 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 20, 2010 |
JP |
2010-235846 |
Claims
1. A heating yarn comprising: an insulating yarn; and a conductive
yarn that is wound around the insulating yarn, wherein 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.
2. The heating yarn according to claim 1, wherein the core yarn is
a high elasticity yarn with an initial tensile resistance of 4.9 to
600 GPa, inclusive.
3. The heating yarn according to claim 1, wherein the core yarn is
a high elasticity yarn with an initial tensile resistance of 54 to
280 GPa, inclusive.
4. The heating yarn according to claim 1, wherein a resin coating
layer is formed on a surface of the plated layer.
5. The heating yarn according to claim 1, wherein the plated layer
is a copper plated layer, and a tin plated layer or a nickel plated
layer is formed on a surface of the copper plated layer.
6. A woven or knitted fabric into which the heating yarn according
to claim 1 is woven or knitted.
Description
INCORPORATION BY REFERENCE
[0001] 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 OF THE INVENTION
[0002] 1. Field of the Invention
[0003] 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.
[0004] 2. Description of Related Art
[0005] 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).
[0006] 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 OF THE INVENTION
[0007] 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.
[0008] 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.
[0009] 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
[0010] 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:
[0011] 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;
[0012] 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;
[0013] 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;
[0014] 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;
[0015] 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;
[0016] 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;
[0017] 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 OF EMBODIMENTS
[0018] 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.
[0019] 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).
[0020] 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.
[0021] 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
108.OMEGA..times.cm.
[0022] 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.
[0023] 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.
[0024] 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.
[0025] 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.
[0026] 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.
[0027] 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 .mu.m, and more preferably 0.3 to 5
.mu.m. 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).
[0028] As described above, the covering layer 13 for inhibiting
oxidation degradation and wear of the plated layer 12 is not
particularly limited. For example, a resin coating layer 13 may be
formed on the surface of the plated layer 12. Accordingly, the
plated layer 12 is protected by the resin coating layer 13, so the
conductive yarn 1 is able to maintain good conductivity. Moreover,
when a connecting member for applying current is connected near
both end portions of a heater member made from a woven or knitted
fabric using the heating yarn 10 of the invention, the resin
coating layer can be peeled away to expose the plated layer, so a
reliable electrical connection can be made. Also, the resin used to
form the resin coating layer is not particularly limited, and may
be a polyurethane resin, a silicon resin, or a polyester resin. A
polyurethane resin is preferable from the perspective of
durability.
[0029] The thickness of the resin coating layer 13 may be set
according to the type of resin and the durability, and the use of
the woven or knitted fabric. For example, the thickness of the
resin coating layer 13 may be 0.1 to 50 .mu.m, or more preferably,
0.5 to 10 .mu.m. Furthermore, the method of forming the resin
coating layer 13 is not particularly limited. For example, a method
whereby the conductive yarn 1 in which the plated layer 12 has been
formed on the peripheral surface of the core yarn 11 is immersed in
a resin-dispersed liquid or passed through the liquid such that
resin adheres to it, and then heated and then cooled such that the
resin becomes fixed may be used. Also, resin powder or melted resin
may be applied or fused to the conductive yarn, and then if
necessary, heated and then cooled such that the resin becomes
fixed.
[0030] Furthermore, when the plated layer 12 formed on the
peripheral surface of the insulating core yarn 11 is a copper
plated layer, a plated layer (i.e., the coating layer 13) made
using a metal that is more oxidation resistant and wear resistant
than copper may be formed as the protective coating layer 13 on the
surface of the copper plated layer by a non-electrolytic plating
method or an electrolytic plating method. Examples of this kind of
plated layer are a tin plated layer and a nickel plated layer. Tin
and nickel are preferable because they do not oxidize as easily as
copper does. The thickness of this plated layer (i.e., the coating
layer 13) may be set according to the type of metal, and the use of
the woven or knitted fabric. For example, the thickness of the
plated layer may be 0.1 to 10 .mu.m, and more particularly 0.3 to 5
.mu.m.
[0031] The woven or knitted fabric of the second example embodiment
of the invention is a woven or knitted fabric into which the
heating yarn of the example embodiment of the invention is woven or
knitted as part, of the constituent yarn, and may be a woven fabric
or a knitted fabric. The woven or knitted fabric of the second
example embodiment is useful as a flat heater member because part
of the constituent yarn is the heating yarn of the example
embodiment of the invention. The woven or knitted fabric of the
second example embodiment may be used as a heating member in a
variety of applications, such as a seat heater, an electric
blanket, an electric carpet, and a snow melting heater. The woven
or knitted fabric of the invention may also be used as a sensor, an
electrode, or an antenna.
[0032] Hereinafter, a case in which the woven or knitted fabric
according to the second example embodiment of the invention is a
knitted fabric 2 that is used as a heater member of a vehicle seat
3 will be described in detail (see FIGS. 5 and 6). This knitted
fabric 2 (see FIG. 5) is not limited to a weft knit or a warp knit,
though a knitted fabric having a weft knit structure is preferable.
A knitted fabric having a weft knit structure can be obtained by
forming loops in a yarn supplied in a course direction and
sequentially interlocking them in a wale direction. This type of
weft knitting is not particularly limited, and `may either be
circular knitting or flat knitting. Also, the type of` weft
knitting machine is also not particularly limited. That is, a
circular knitting machine or a flat knitting machine may be used.
In either case, a single bed knitting machine or a double bed
knitting machine may be used. Moreover, examples of the knitting
machine are a plain knitting machine or a Jacquard knitting
machine, and either may be used.
[0033] The interval between a plurality of heating yarns 10 that
are knitted in as part of the constituent yarn is not particularly
limited (see FIG. 5). This interval is preferably approximately 1
to 100 mm, and more preferably approximately 5 to 60 mm. Also, the
arrangement of the heating yarns in the wale direction of the
knitted fabric [the longitudinal direction in a seat cushion of a
vehicle seat (see the seat cushion 31 in FIG. 6) and the vertical
direction in a seat back (see the seat back 32 in FIG. 6)] is not
particularly limited. That is, the heating yarns may be knitted in
at substantially equidistant intervals or the intervals may not be
equidistant. If the heating yarns are knitted in at substantially
equidistant intervals, the entire seat cushion and seat back can be
warmed more evenly. On the other hand, if there is a desire to warm
a specific area of a seated person, such as the thighs, shoulders,
or back, for example, more thoroughly, the heating yarns may be
arranged relatively close together at the area corresponding to the
heating member (i.e., see heating members 331 and 332 in FIG. 6),
and relatively farther apart at other areas.
[0034] Moreover, the heating yarns may be such that only one
heating yarn is knit in between non-heating yarns, or a plurality
of heating yarns may be knit in between non-heating yarns, e.g., 2
to 10, and more particularly 2 to 5 heating yarns may be knit in
consecutively between non-heating yarns. In this case as well, the
arrangement of the plurality of heating yarns knitted in
consecutively in the wale direction of the knitted fabric may be a
substantially equidistant arrangement or not an equidistant
arrangement. In this way, whether the seat cushion and the seat
back of the vehicle seat are warmed evenly, or whether a specific
area is warmed more thoroughly, can be adjusted according to the
interval at which the heating yarns are arranged, and the number of
heating yarns that are consecutively knitted in, and the like.
[0035] With this heater member, the connecting member for
connecting the heating yarns to an ECU are connected near both end
portions of each heating yarn. Power is supplied from a power
supply by a signal from the ECU, such that the heating yarns are
heated, causing the heater member to rise in temperature. At this
time, the non-heating yarns, and the insulating yarns and the
conductive yarns (i.e., the core yarns, the plated layer, and the
resin coating layer and the like) of the heating yarns, that are
knitted in are mixed near both end portions of the heater member.
Therefore, when the non-heating yarn and the resin coating layer
are provided, at least the resin coating layer must be removed
before attaching the connecting member.
[0036] The method for removing the non-heating yarn is not
particularly limited. For example, the non-heating yarn and the
like may be efficiently removed by heating the areas near both end
portions of the heater member such that the non-heating yarn melt
or burn off. Therefore, of the insulating yarn and the core yarn of
the conductive yarn that form the heating yarn, it is preferable
that at least the core yarn be more heat resistant than the
non-heating yarn. In other words, it is preferable that the
temperature at which the core yarn will melt from being heated, or
the decomposition temperature in a case in which the core yarn does
not melt, be higher than that of the non-heating yarn. That is, it
is preferable that the core yarn (or the heating yarn) have a
higher melting point than the non-heating yarn, or that the core
yarn (or the heating yarn) not burn as easily as the non-heating
yarn. Even if the core yarn is a yarn that will melt, the
non-heating yarn can easily be removed by being burned off. Also,
even when both the non-heating yarn and the core yarn and the like
are yarns that will melt, at least the core yarn, from among the
insulating yarn and the core yarn of the conductive yarn that form
the heating yarn, is preferably a yarn that does not burn as easily
as the non-heating yarn.
[0037] As described above, when removing both end portions of the
heating yarn, the core yarn is a flame retardant, high elasticity
yarn, so the melting point and the decomposition temperature can be
raised higher than they are with a polyester fiber or the like that
is often normally used as non-heating yarn. Therefore, the
non-heating yarn can easily be removed by heating it at a
temperature at which it will melt and the core yarn will not melt.
Meanwhile, a polyester fiber or the like is also often used as
insulating yarn around which the conductive yarn is wound. In this
case, this insulating yarn can be removed just like the non-heating
yarn, according to the difference in the melting points.
[0038] The limiting oxygen index (LOI) measured in compliance with
JIS K7201 and JIS L1091 (1999) 8.5 E-2 may be used as the
combustibility index. The LOI of the flame retardant, high
elasticity yarn used as the core yarn is normally 25 or higher, and
more preferably 28 to 68. On the other hand, the LOI of the
polyester fiber that forms the non-heating yarn is normally 18 to
20, and the LOI of an aliphatic polyamide fiber such as Nylon 6 is
normally 20 to 22. Both are considerably lower than that of the
flame retardant, high elasticity yarn, so the non-heating yarn
burns more easily than the high elasticity yarn does, making them
easily able to be removed by being burned off.
[0039] The heating method is not particularly limited. Some
examples include a method according to exothermal heating that
involves contacting the yarn or the like with a heating member, and
a method that involves emitting a laser such as a carbon dioxide
laser, a YAG laser, or an excimer laser. The method of emitting a
laser is preferable.
[0040] If the method of emitting a laser is used, the strength and
output of the laser can be easily adjusted to the level needed to
melt or burn off the non-heating yarn by the material and the like
of the non-heating yarn, thus making it possible to efficiently
remove the non-heating yarn and the like. Moreover, the laser may
be emitted from either surface of the heater member. Emitting the
laser with the focal point offset with respect to the surface of
the heater member temporarily enables a wider area to be worked.
Also, the non-heating yarn and the like is able to be removed in
strips after emitting the laser back and forth in the wale
direction. Further, spraying an inert gas, such as nitrogen gas or
helium gas, while emitting the laser makes it possible to prevent,
or at least reduce, oxidation degradation of the plated layer that
occurs due to overheating.
[0041] Hereinafter, a first example of the invention will be
described in detail. A 330 dtex, 72 filament polyethylene
terephthalate (hereinafter referred to as "PET") multifilament
false twist textured yarn was used as the insulating yarn. Also, a
28 dtex, 5 filament polyarylate fiber (high elasticity yarn,
initial tensile resistance of 74 GPa, trade name Vectran by
Kuraray) was used as the core yarn. A copper plated layer 0.30
.mu.m thick was formed on the peripheral surface of this core yarn,
and then a nickel plated layer 0.20 .mu.m thick was formed on the
surface of the copper plated layer. This core yarn with a copper
plated layer and a nickel plated layer was used as the conductive
yarn. The heating yarn was manufactured by covering the surface of
the insulating yarn with 500 T/m of the conductive yarn in the S
and Z directions. Next, the conductive yarn was thermoset to
prevent it from coming out of its predetermined position. In this
way, a double covering yarn with a resistance value of 1.0.OMEGA.
per unit length (1 cm) was manufactured.
[0042] Then, a double jersey knitted fabric was knitted using a
both-side needle selection machine (Precision Fukuhara Works, Ltd.,
model V-LEC4DS, 30 inch diameter unit pattern, 18 gauge, 48
feeders) as the weft knitting machine. Twenty-four strands of yarn
were used, some of which were heating yarn (the double covering
yarn). Also, three types of other wire [first wire: spun-dyed PET
textured yarn (color: beige, 334 dtex, 48 filaments), second wire:
PET textured yarn, (normal texture, 167 dtex, 48 filaments), and
third wire: PET textured yarn (strong textured yarn, 334 dtex, 48
filaments)] were used.
[0043] Also, for knitting, 24 of the 48 feeders were used as
feeders, and the first wire was supplied from feeders with feeder
numbers of (1 and multiples of 4+1). Also, the second wire was
supplied from feeders with supply path numbers of (even numbers
excluding 4 and multiples of 4+3). Further, the heating yarn was
supplied from the feeder of feeder number (3), and the third wire
was supplied from the feeder of feeder number (4). The knit
structure organization chart of 9 to 12 was repeatedly used for
feeder numbers 13 to 24. The interval between heating yarns was 10
mm. Also, visual monitoring was performed to check whether or not
there were any breaks in the heating yarn when knitting the knitted
fabric, and no breaks were observed.
[0044] Then, the knitted fabric knitted in this way was first
refined (i.e., desized at 80.degree. C.), then subjected to an
intermediate thermoset (at 150.degree. C. for 1 minute), and then
resin processed (immersed in an aqueous dispersion in which wax and
polyurethane resin have been dispersed, and then dried). Then one
side of the knitted fabric was coated with a flame retardant
coating, after which it was subjected to a finishing set. Also, a
pad material (i.e., a polyurethane resin sheet 5 mm thick) and a
back base cloth (half tricot of 15 dtex Nylon 6) were arranged in
that order on the back side of the cloth. Then the other surface of
the knitted fabric processed as described above was laid over the
back base cloth, and a laminated member for a seat was manufactured
by integrating the two together by a frame lamination method.
[0045] Then, a cover piece of predetermined dimensions was cut out
as a main member of the seat sitting surface by emitting a laser on
the laminated member for a seat. To emit the laser, a carbon
dioxide laser processing machine (by Mitsubishi; Type: 2512H2;
Transmitter type: 25SRP; Laser rated output: 1,000 W) was used. The
emitting conditions were: Speed: 500 mm/minute; Output: 30 W; Duty:
7.7%; and Frequency: 200 Hz. Furthermore, at a position 15 mm from
the end portion of both ends of the cover piece, the laser was
emitted from the back side (i.e., the side where the knitted fabric
was overlaid), swept in the length direction, and melted, thus
cutting, the pad material, the back base cloth, the insulating
yarn, and the first to third wires. The emitting conditions were:
Speed 1,500 mm/minute; Output: 20 W; Duty: 7.7%; and Frequency: 200
Hz. The conductive yarn was not melted by the laser emission, but
instead remained. The plated layer was also not affected by the
laser emission.
[0046] Next, the end portions of the conductive yarn was exposed by
peeling away both end portions of the cover piece and removing the
pad material, the back base cloth, the insulating yarn, and the
first to third wires. Further, a strip of connecting member was
sewn onto the surface of the cover piece, and then the conductive
yarn and the connecting member were sewn together.
[0047] A second example of the invention will be described. For the
heating yarn, heating yarn just like that in the first example was
used, and this was used as a first weft yarn. Also, for another
wire, a dyed-in PET memory-twisted textured yarn (color: light
gray; 167 dtex/2; 144 filaments) was used as a warp yarn and a
second weft yarn. Also, using a Jacquard knitting machine, the warp
yarn was prepared (124 strands/2.5 cm), and then a cloth raw fabric
with a weft yarn density of 50 strands/2.54 cm was woven by
punching in the first weft yarn and the second weft yarn.
[0048] Then, the cloth raw fabric was refined (i.e., desized at
80.degree. C.) and subjected to an intermediate thermoset (at
150.degree. C. for 1 minute), and then a backing agent was adhered
to the side that would be the back side of the finished product and
dried, thus creating cloth. The main components of the backing
agent used were an acrylic-type polymer, made by copolymerizing
butyl acrylate and acrylonitrile, and a flame retardant. As, the
amount of backing agent applied was 45 g/m2, and the drying
conditions were 1 minute at 150.degree. C.
[0049] The finished density of the cloth was a warp of 135
strands/2.54 cm, a weft of 55 strands/2.54 cm, and 5% modulus of
the cloth was 98 N for the warp and 33 N for the weft. Then, a pad
material (i.e., a polyurethane resin sheet 5 mm thick) and a back
base cloth (half tricot of 15 dtex Nylon 6) were arranged in that
order on the back side of the cloth. Then a laminated member for a
seat was manufactured by integrating the two together by a frame
lamination method. Next, just as in the first example, the end
portions of the conductive yarn were exposed, a strip of connecting
member was attached by sewing to the surface of the cloth, and then
the conductive yarn and the connecting member were sewn
together.
[0050] A third example of the invention will be described. 330
dtex, 72 filament PET multifilament memory-twisted textured yarn
was used as the insulating yarn, Also, 14 dtex, single filament
polyacrylate fiber (high elasticity yarn; initial tensile
resistance of 74 GPa; trade name Vecry by Kuraray) was used as the
core yarn. A copper plated layer 0.38 .mu.m thick was formed on the
peripheral surface of this core yarn. Then, a dispersion liquid in
which a polyurethane-based resin had been dispersed in a
water-based medium and adjusted was applied to the surface of the
copper plated layer formed on the peripheral surface of the core
yarn and dried, thereby forming a resin coating 1.0 .mu.m thick.
This core yarn with a copper plated layer and resin coating was
used as the conductive yarn. The heating yarn was manufactured by
covering the surface of the insulating yarn with 500 T/m of the
conductive yarn in the S and Z directions. Next, the conductive
yarn was thermoset to prevent it from coming out of its
predetermined position. In this way, a double covering yarn with a
resistance value of 2.8.OMEGA. per unit length (1 cm) was
manufactured. Then, cloth raw fabric was manufactured just as in
the second example using this double covering yarn (i.e., the
heating yarn) as the first weft yarn. Next, just as in the second
example, the cloth and the laminated member for a seat were
manufactured, and the end portions of the conductive yarn were
exposed and the conductive yarn and the connecting member were sewn
together in the same way.
[0051] Then, a seat cover was manufactured by sewing side material
to an outer side of one of the woven or knitted fabrics obtained by
the first to the third examples, and this seat cover was fit onto a
seat cushion. Also, for comparison, a seat cover of the same
structure, other than that the heated yarn was not woven or knitted
into the woven or knitted fabric and the end portions of the
conductive yarn were not connected to the connecting member, was
manufactured and fit on a seat cushion. In this case, a seat heater
in which a conductive wire made of a resin-covered 1.5 mm diameter
nichrome wire was adhered to a nonwoven cloth surface was placed
under an expanded polyurethane sheet 5 mm thick and over a pad made
using a polyurethane resin sheet.
[0052] There was no difference in the cut of the vehicle seat (see
the vehicle seat 3 in FIG. 3) that used the woven or knitted fabric
(i.e., a woven fabric having a weft weave structure; see the
knitted fabric 2 in FIG. 5) of the second example embodiment of the
invention manufactured in this way as the heater member, and the
comparative seat. However, regarding the sitting comfort of the
seat cushion (see the seat cushion 31 of the vehicle seat 3 in FIG.
6), discomfort from the hardness of the conductive wire was felt
with the comparative seat, while no discomfort at all was felt with
the seat using the woven or knitted fabric of the second example
embodiment of the invention as the heater member. In fact, the seat
using the woven or knitted fabric of the second example embodiment
as the heater member had a good feel to it.
[0053] The description given above is merely for descriptive
purposes and should in no be way construed as limiting the
invention. While the invention is described giving classic examples
and example embodiments, the language used in the descriptions and
the drawings of the invention is understood to be in no way
limiting, but rather descriptive and exemplary. As described in
detail here, the example embodiments may be modified within the
scope of the accompanying claims for patent, without departing from
the spirit and scope of the invention. Here, references are made to
the specific structure, material, and examples described in detail
of the invention, but the invention is not intended to be limited
to the descriptions here. Rather, the invention covers all
functionally equivalent structures, methods, and uses within the
scope of the accompanying claims for patent.
[0054] The invention may be used in the technical field of heating
seats that can generate heat and rise in temperature. In
particular, the invention is useful in the commercial product field
of heater members that can be used out of doors, such as in a seat
of a vehicle such as a passenger vehicle.
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