Electric heating/warming woven fibrous articles

• US 6,888,112 B2
• Filed: 02/25/2002
• Issued: 05/03/2005
• Est. Priority Date: 04/22/1999
• Status: Expired due to Fees

• Current Assignee: MMI-IPCO LLC
• Original Assignee: Malden Mills Industries Incorporated (Milliken & Company)
• Inventors: Rock, Moshe, Sharma, Vikram
• Primary Examiner(s): DAHBOUR, HENRY
• Application Number:
  US10/082,465
• Publication Number:
  US 20020104837A1
• Time in Patent Office: 1,163 Days
• Field of Search: 219/545, 219/211, 219/212, 219/213, 219/527, 219/528, 219/529, 219/542, 219/543, 219/549, 29/91, 29/911, 661/70, 661/71, 661/91, 661/92, 661/94, 661/95, 428/89
• US Class Current: 219/545
• CPC Class Codes: A41D 13/0051 Heated garments heated divers' suits B63C11/28
• CPC Class Codes: D03D 1/00 Woven fabrics designed to make specified articles
• CPC Class Codes: D03D 1/0088 Fabrics having an electronic function
• CPC Class Codes: D03D 15/00 Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
• CPC Class Codes: D03D 15/25 Metal
• CPC Class Codes: D03D 15/283 synthetic polymer-based, e.g. polyamide or polyester fibres cellulose-based artificial fibres D03D15/225
• CPC Class Codes: D03D 15/47 multicomponent, e.g. blended yarns or threads multicomponent fibres or filaments D03D15/292
• CPC Class Codes: D03D 15/533 antistatic; electrically conductive
• 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 2101/20 Metallic fibres
• CPC Class Codes: D10B 2201/02 Cotton
• CPC Class Codes: D10B 2201/24 Viscose
• CPC Class Codes: D10B 2211/02 Wool
• CPC Class Codes: D10B 2321/022 polypropylene
• CPC Class Codes: D10B 2321/10 polymers of unsaturated nitriles, e.g. polyacrylonitrile, polyvinylidene cyanide
• CPC Class Codes: D10B 2331/02 polyamides D10B2331/08 takes precedence
• CPC Class Codes: D10B 2331/04 polyesters, e.g. polyethylene terephthalate [PET]
• CPC Class Codes: D10B 2401/021 hydrophobic
• CPC Class Codes: D10B 2401/022 hydrophylic
• CPC Class Codes: D10B 2401/16 : antistatic; conductive
• CPC Class Codes: D10B 2501/00 : Wearing apparel
• CPC Class Codes: D10B 2503/06 : Bed linen
• 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 2203/015 : Heater wherein the heating element is interwoven with the textile
• 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 3/342 : heaters used in textiles
• CPC Class Codes: H05B 3/345 : knitted fabrics
• CPC Class Codes: H05B 3/347 : woven fabrics

Abstract

A woven fibrous article that generates heat upon application of electrical power has a woven fibrous body consisting of a set of non-conductive warp yarns and a set of non-conductive filling or weft yarns. One of the set of non-conductive warp yarns and the set of non-conductive filling or weft yarns, in one or more first regions, consists of relatively more coarse yarns and in one or more second regions consists of relatively more fine yarns with electrical conductor elements extending generally along the second regions of the woven fibrous body to connect the plurality of spaced apart electrical conductance heating elements in a parallel electrical circuit to a source of electrical power. The other of the set of non-conductive warp yarns and the set of non-conductive filling or weft yarns, in the one or more first regions and in the one or more second regions, consists of relatively more fine yarns, with a plurality of spaced apart electrical conductance heating elements in the form of conductive elements joined in the woven fibrous body with the other of the set of non-conductive warp yarns and the set of non-conductive filling or weft yarns to extend generally between opposite the second regions of the woven fibrous body. In one embodiment, fleece may be formed on one or both surfaces of the woven fibrous body by finishing fibers of the relatively more coarse yarns in the one or more first regions of the set of non-conductive warp yarns or non-conductive filling or weft yarns, in a manner to avoid damage to electrical conductivity performance of the conductive elements joined with the set of yarns of the woven fibrous body. A method of forming a woven fibrous article of the invention is also described.

Claims

1. A woven fibrous article adapted to generate heat upon application of electrical power, comprising:

a woven fibrous body comprised of a set of non-conductive warp yarns and a set of non-conductive filling or weft yarns,

one of said set of non-conductive warp yarns and said set of non-conductive filling or weft yarns in one or more first regions comprising relatively more coarse yarns and in one or more second regions comprising relatively more fine yarns with electrical conductor elements extending generally along said second regions of said woven fibrous body and adapted to connect a plurality of spaced apart electrical conductance heating elements in a parallel electrical circuit to a source of electrical power, and

the other of said set of non-conductive warp yarns and said set of non-conductive filling or weft yarns in the one or more first regions and in the one or more second regions comprising relatively more fine yarns, with said plurality of spaced apart electrical conductance heating elements in the form of conductive elements joined in said woven fibrous body with the other of said set of non-conductive warp yarns and said set of non-conductive filling or weft yarns to extend generally between opposite said second regions of said woven fibrous body.

2. The woven fibrous article of claim 1, where said woven fibrous article further comprises fleece upon at least one surface of said woven fibrous body, formed by finishing fibers of the relatively more coarse yarns in said one or more first regions of said one of said set of non-conductive warp yarns and said set of non-conductive filling or weft yarns in a manner to avoid damage to electrical conductivity performance of the conductive elements joined with the other of said set of non-conductive warp yarns and said set of non-conductive filling or weft yarns of said woven fibrous body.

3. The woven fibrous article of claim 2, wherein said woven fibrous body has fleece formed in said relatively more coarse non-conductive fibers upon both surfaces.

4. The woven fibrous article of claim 1, wherein, in said one or more first regions, said set of non-conducting warp yarns comprises said relatively more coarse yarns and said set of non-conducting filling or well yarns comprises said relatively more fine yarns.

5. The woven fibrous article of claim 4, wherein said one or more second regions comprises selvedge or edge regions.

6. The woven fibrous article of claim 1, wherein, in said one or more first regions, said set of non-conducting filling or well yarns comprises said relatively more coarse yarns and said set of non-conducting warp yarns comprises said relatively more fine yarns.

7. The woven fibrous article of claim 6, wherein said one or more second regions comprises spaced regions with one or more said first regions disposed therebetween.

8. The woven fibrous article of claim 6 or claim 7, wherein said one or more second regions comprises a plurality of spaced second regions with one or more said first regions disposed therebetween.

9. The woven fibrous article of claim 1, claim 4 or claim 6, wherein a series of at least three electrical conductance heating elements of said plurality of electrical conductance heating elements are symmetrically spaced.

10. The woven fibrous article of claim 9, wherein selected of said electrical conductance heating elements are asymmetrically spaced to provide selected localized regions of heating.

11. The woven fibrous article of claim 1, claim 4 or claim 6, wherein selected of said electrical conductance heating elements are asymmetrically spaced to provide selected localized regions of heating.

12. The woven fibrous article of claim 1, claim 4 or claim 6, wherein selected of said conductive elements have relatively lower linear resistance than other of said conductive elements, to provide selected localized regions of relatively greater heating.

13. The woven fibrous article of claim 12, wherein said selected of said conductive elements of relatively lower linear resistance are symmetrically spaced.

14. The woven fibrous article of claim 13, wherein said selected of said conductive elements of relatively lower linear resistance are asymmetrically spaced.

15. The woven fibrous article of claim 1, wherein said conductive elements have the form of a conductive yarn.

16. The woven fibrous article of claim 1, wherein said fibrous body comprises hydrophilic material.

17. The woven fibrous article of claim 1, wherein said fibrous body comprises hydrophobic material.

18. The woven fibrous article of claim 1, wherein said electrical conductor elements are adapted for connecting said plurality of spaced-apart electrical conductance heating elements in the parallel electrical circuit to a power source of alternating current.

19. The woven fibrous article of claim 1, wherein said electrical conductor elements are adapted for connecting said plurality of spaced-apart electrical conductance heating elements in the parallel electrical circuit to a power source of direct current.

20. The woven fibrous article of claim 19, wherein said power source of direct current comprises a battery.

21. The woven fibrous article of claim 20, wherein said battery is mounted to said woven fibrous body.

22. The woven fibrous article of claim 1, wherein said woven fibrous article further comprises a power source connected to said plurality of spaced apart electrical conductance heating elements by said electrical conductor elements, said power source comprising a battery mounted to said woven fibrous body.

23. The woven fibrous article of claim 1, wherein said electrical conductor elements are woven into said second regions of said woven fibrous body.

24. The woven fibrous article of claim 4, wherein said electrical conductor elements are woven into said second regions of said woven fibrous body with said non-conductive warp yarns.

25. The woven fibrous article of claim 6, wherein said electrical conductor elements are incorporated into said second regions of said woven fibrous body with said non-conductive filling or weft yarns.

26. The woven fibrous article of claim 23, claim 24 or claim 25, wherein said electrical conductor elements comprise at least two yarns.

27. The woven fibrous article of claim 1, wherein said electrical conductor elements, at least in part, are applied as a conductive paste.

28. The woven fibrous article of claim 1, wherein said electrical conductor elements comprise a conductive wire.

29. The woven fibrous article of claim 1, wherein said electrical conductor elements, at least in part, are applied as a conductive hot melt adhesive.

30. The woven fibrous article of claim 1, wherein said electrical conductor elements comprise a conductive yarn or a conductive thread.

31. The woven fibrous article of claim 1, wherein said electrical conductor elements are attached upon a surface in a said second region of said woven fibrous body.

32. The woven fibrous article of claim 31, wherein said electrical conductor elements are attached by stitching.

33. The woven fibrous article of claim 32, wherein said stitching comprises embroidery stitching.

34. The woven fibrous article of claim 31, wherein said electrical conductor elements are attached by sewing.

35. The woven fibrous article of claim 31, wherein said electrical conductor elements are attached by adhesive.

36. The woven fibrous article of claim 31, wherein said electrical conductor elements are attached by laminating.

37. The woven fibrous article of claim 31, wherein said electrical conductor elements are attached by mechanical fastening.

38. The woven fibrous article of claim 31, wherein said electrical conductor elements are attached by strain relief fastening.

39. The woven fibrous article of claim 1, wherein said electrical conductance heating element has the form of a conductive yarn comprising a core, an electrical conductance heating filament, and a sheath material wrapped about said core.

40. The woven fibrous article of claim 39, wherein said core comprises said electrical conductance heating element and said sheath comprises insulating material.

41. The woven fibrous article of claim 39, wherein said core comprises insulating material and said sheath wrapped about said core comprises said electrical conductance heating element.

42. The woven fibrous article of claim 41, wherein said electrical conductance heating element further comprises an overwrap comprising insulating material wrapped about said core and said sheath.

43. The woven fibrous article of claim 1, wherein said electrical conductance heating element has the form of a conductive yarn comprising an electrical conductance heating filament.

44. The woven fibrous article of claim 39, claim 40, claim 41, claim 42, or claim 43, wherein said electrical conductance heating element has electrical resistivity in the range of about 0.1 ohm/cm to about 500 ohm/cm.

45. A woven fibrous article adapted to generate heat upon application of electrical power, formed by a method comprising the steps of:

joining a set of non-conductive warp yarns and a set of non-conductive filling or weft yarns to form a woven fibrous body, one of the set of non-conductive warp yarns and the set of non-conductive filling or weft yarns in one or more first regions comprising relatively more coarse yarns and in one or more second regions comprising relatively more fine yarns and the other of the set of non-conductive warp yarns and the set of non-conductive filling or weft yarns in the one or more first regions and in the one or more second regions comprising relatively more fine yarns,

joining, in the woven fibrous body, with the other of the set of non-conductive warp yarns and the set of non-conductive filling or weft yarns, the plurality of spaced apart electrical conductance heating elements in the form of conductive elements, to extend generally between opposite second regions of the woven fibrous body, and

connecting the plurality of spaced apart electrical conductance heating elements to electrical conductor elements extending generally along the second regions of the woven fibrous body in a manner to form a parallel electrical circuit for connection to a source of electrical power.

46. The method of forming the fibrous article of claim 45, said method further comprising the step of:

finishing relatively more coarse yarns fibers in the one or more first regions of the set of the non-conductive warp yarns and the set of non-conductive filling or weft yarns in a manner to avoid damage to electrical conductivity performance of the conductive elements joined with the other of the set of non-conductive warp yarns and the set of non-conductive filling or weft yarns of the woven fibrous body.

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

joining a set of non-conductive warp yarns and a set of non-conductive filling or weft yarns to form a woven fibrous body, one of the set of non-conductive warp yarns and the set of non-conductive filling or weft yarns in one or more first regions comprising relatively more coarse yarns and in one or more second regions comprising relatively more fine yarns and the other of the set of non-conductive warp yarns and the set of non-conductive filling or weft yarns in the one or more first regions and in the one or more second regions comprising relatively more fine yarns,

joining, in the woven fibrous body, with the other of the set of non-conductive warp yarns and the set of non-conductive filling or weft yarns, the plurality of spaced apart electrical conductance heating elements in the form of conductive elements, to extend generally between opposite second regions of the woven fibrous body, and

connecting the plurality of spaced apart electrical conductance heating elements to electrical conductor elements extending generally along the second regions of the woven fibrous body to form a parallel electrical circuit for connection to a source of electrical power.

48. The method of claim 47, further comprising the steps of:

finishing relatively more coarse yarns fibers in the one or more first regions of the set of the non-conductive warp yarns and the set of non-conductive filling or weft yarns in a manner to avoid damage to electrical conductivity performance of the conductive elements joined with the other of the set of non-conductive warp yarns and the set of non-conductive filling or weft yarns of the woven fibrous body.

49. The method of claim 47 further comprising the step of connecting the conductive element to a source of electric power and generating heat.

50. The method of claim 49 further comprising the step of connecting the conductive element to a source of electric power comprising alternating current and generating heat.

51. The method of claim 49 further comprising the step of connecting the conductive element to a source of electric power comprising direct current and generating heat.

52. The method of claim 51 further comprising the step of connecting the conductive element to a source of electric power comprising direct current in the form of a battery and generating heat.

53. The method of claim 52 further comprising the step of connecting the conductive element to a source of electric power comprising direct current in the form of a battery mounted to the woven fibrous article and generating heat.

54. The method of claim 47 further comprising the step of rendering elements of said woven fibrous body hydrophilic.

55. The method of claim 47 further comprising the step of rendering elements of said woven fibrous body hydrophobic.