Electric heating/warming fabric articles

• US 6,501,055 B2
• Filed: 03/22/2001
• Issued: 12/31/2002
• Est. Priority Date: 04/22/1999
• Status: Expired due to Fees

• Current Assignee: MMI-IPCO LLC
• Original Assignee: Malden Mills Industries Incorporated (Polartec LLC)
• Inventors: Rock, Moshe, Sharma, Vikram
• Primary Examiner(s): Walberg, Teresa
• Assistant Examiner(s): Dahbour, Fadi H.
• Application Number:
  US09/814,896
• Publication Number:
  US 20010019050A1
• Time in Patent Office: 649 Days
• Field of Search: 219/545, 219/529, 219/211, 219/212, 219/213, 219/217, 219/527, 219/528, 219/549, 338/208, 66/61, 66/80, 66/83, 661/69.R, 661/71, 661/70, 661/82, 661/90, 661/91, 661/92, 661/93, 661/94, 661/95, 662/02, 296/101, 296/11, 29/91, 29/911
• US Class Current: 219/545
• CPC Class Codes: D04B 1/04 characterised by thread material
• CPC Class Codes: D04B 1/14 Other fabrics or articles characterised primarily by the use of particular thread materials
• CPC Class Codes: D10B 2401/16 antistatic; conductive
• CPC Class Codes: H05B 2203/005 using multiple resistive elements or resistive zones isolated from each other
• CPC Class Codes: H05B 2203/011 Heaters using laterally extending conductive material as connecting means
• CPC Class Codes: H05B 2203/014 Heaters using resistive wires or cables not provided for in H05B3/54
• CPC Class Codes: H05B 2203/017 Manufacturing methods or apparatus for heaters
• CPC Class Codes: H05B 2203/036 Heaters specially adapted for garment heating
• CPC Class Codes: H05B 3/345 knitted fabrics
• CPC Class Codes: H05B 3/347 woven fabrics

Abstract

A fabric article that generates heat upon application of electrical power is formed, for example, by joining stitch and loop yarns to form a fabric prebody, with the loop yarn overlaying the stitch yarn at a technical face and forming loops at a technical back of the fabric prebody. An electrical resistance heating element, e.g., in the form of a conductive yarn, is incorporated into the fabric prebody at symmetrical and/or asymmetrical spaced-apart intervals as the stitch yarn, the electrical resistance heating elements extending between opposite edge regions of the fabric and conductor elements, e.g. located along edge regions, connect the electrical resistance heating elements to a source of electrical power. The technical face and/or the technical back of the fabric body may have fleece formed by finishing in a manner to avoid damage to electrical conductance of the electrical resistance heating elements. Preferably, the conductive yarn has a core of insulating material, an electrical resistance-heating element about the core, and a sheath material surrounding the electrical resistance heating element and core.

Claims

1. A method of forming a fabric article adapted to generate heat upon application of electrical power, said method comprising the steps of:

joining, in a continuous web, by a reverse plaiting circular knitting process, a stitch yarn and a loop yarn to form a fabric prebody, with the loop yarn overlaying the stitch yarn at a technical face and forming in loops at a technical back of the fabric prebody;

at spaced-apart intervals during the knitting process, incorporating into the fabric prebody as the stitch yarn an electrical resistance-heating element;

transforming the fabric prebody into a fabric body, with the electrical resistance heating elements extending between opposite edge regions of the fabric body;

finishing at least one of the technical face and the technical back of the fabric body, in a manner avoiding damage to electrical conductance of the electrical resistance heating elements, to form a fleece surface region; and

providing conductor elements for connecting the electrical resistance heating elements to a source of electrical power.

2. The method of claim 1, comprising the further step of finishing at least one of said technical face and said technical back of the fabric body, in a manner avoiding damage to electrical conductance of the electrical resistance heating elements, to form a fleece surface region.

3. The method of claim 1, comprising the further steps of finishing the technical face of the fabric body, in a manner to avoid damage to electrical conductance of the electrical resistance heating elements, to form a first fleece surface region, and finishing the technical back of the fabric body in a manner to avoid damage to electrical conductance of the electrical resistance heating elements to form a second fleece surface region.

4. The method of claim 1, comprising the further step of applying, directly to the continuous web, the conductor elements for connecting the electrical resistance heating elements to a source of electrical power.

5. The method of claim 1, comprising the further step of incorporating into the fabric prebody the electrical resistance heating element in the form of a conductive yarn comprising a core of insulating material and at least one electrical resistance heating filament disposed generally about said core.

6. The method of claim 1 comprising the further step of connecting the conductor elements to a source of electric power and generating heat.

7. The method of claim 6 comprising the further step of connecting the conductor elements to a source of electric power comprising alternating current and generating heat.

8. The method of claim 6 comprising the further step of connecting the conductor elements to a source of electric power comprising direct current and generating heat.

9. The method of claim 8 comprising the further step of connecting the conductor elements to a source of electric power comprising direct current in the form of a battery and generating heat.

10. The method of claim 9 comprising the further step of connecting the conductor elements to a source of electric power comprising direct current in the form of a battery mounted to the fabric article and generating heat.

11. The method of claim 1 comprising the further steps of:

limiting formation of loops to a central region of the fabric prebody, the central region being disposed between a pair of edge regions in the fabric body, and

providing the conductor elements for connecting the electrical resistance heating elements to a source of electrical power in the edge regions of the fabric body.

12. The method of claim 1 comprising the further steps of:

limiting formation of loops to a plurality of central regions of the fabric prebody, each of the plurality of central regions extending in a continuous web direction and being disposed between a pair of edge regions in the fabric body, and

providing the conductive elements for connecting the electrical heating elements to a source of electrical power in the edge regions of the fabric body.

13. The method of claim 12 comprising the further step of separating the continuous web in a continuous web direction to form a plurality of discrete panels of limited width transverse to the continuous web direction, each of said discrete panels having a central region with loops disposed between edge regions with conductive elements.

14. The method of claim 13 comprising the further step of severing the panels generally transverse to the continuous web direction to form discrete heating pad elements.

15. The method of claim 1 comprising the further step of rendering the yarns of said fabric body hydrophilic.

16. The method of claim 1 comprising the further step of rendering the yarns of said fabric body hydrophobic.

17. The method of claim 1, comprising the further step of incorporating into the fabric prebody the electrical resistance heating-element in the form of a conductive yarn.