Heating Textile With Carbon Yarn Resistance And Reflective Layer

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Solution Overview

Problem

Existing textile heating articles with integrated electrical resistance layers are costly to manufacture due to expensive integration methods and limited design versatility, and they have inefficiencies in energy conversion and heat distribution.

Innovation Solution

A multilayer textile article with a heating layer made from a crochet-type warp knitting fabric that integrates a carbon yarn electrical resistance directly powered from the mains, eliminating the need for conductive electrodes and allowing for versatile design and efficient heat distribution through a reflective layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If electrical resistance is integrated into the heating layer using mechanical binding or sewing, then the heating function is achieved, but the manufacturing cost increases significantly

Engineering Contradiction:

Improveheating functionVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the electrical resistance element directly into the fabric structure during the knitting process. The heating element is integrated as part of the woven fabric itself, eliminating the need for separate mechanical binding or sewing operations to attach resistance elements to the heating layer, thereby significantly reducing manufacturing costs while maintaining the heating function.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The electrical resistance is incorporated into the fabric during the initial knitting process rather than being added later as a separate step. This preliminary integration of the heating element into the fabric structure avoids subsequent expensive assembly operations and simplifies the overall manufacturing process.

Inventive Principle:

Principle #10Preliminary action

2Stability of the object's composition

If conventional weaving methods are used to create the heating layer, then the structure is stable, but the design versatility and heat distribution uniformity are limited

Engineering Contradiction:

Improvefabric structureVSAvoiddesign versatility

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The patent employs a knitted fabric structure rather than conventional woven fabric. The knitted construction provides inherent flexibility and adaptability, allowing the heating element to conform to various shapes and configurations while maintaining structural stability. This dynamic fabric structure enables greater design versatility and more uniform heat distribution across different application geometries.

Inventive Principle:

Principle #15Dynamics

3Reliability

If electrical resistance is integrated into the heating layer, then heat generation is achieved, but the energy conversion efficiency is reduced

Engineering Contradiction:

Improveheat generationVSAvoidenergy conversion efficiency

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent positions the electrical resistance elements strategically within the fabric structure to optimize heat generation and distribution. By locally optimizing the resistance placement and configuration within the knitted fabric, the system achieves more efficient energy conversion to heat while minimizing energy losses, improving overall thermal efficiency compared to conventional approaches.

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution reduces manufacturing costs, enhances energy efficiency, and allows for uniform heat distribution across the textile article, enabling a wide range of applications from floor heating to clothing and industrial uses.

Implementation Method 1

a heating layer (10d) incorporating an electrical resistance (R) suitable to be supplied with an electric current (I) so as to warm up by Joule effect

Methodology Applied

Scientific EffectJoule effect: Joule Heating

Implementation Method 2

a reflective layer (10c), inner, made of a heat-reflective material, superimposed on the second layer (10b) on the opposite side with respect to the first layer (10a)

Methodology Applied

Scientific EffectReflection: Reflection

Data Source

PatentUS9883550B2Multilayer textile article with an inner heating layer made of an electrified fabric, and respective manufacturing process

Publication Date: 2018.01.30 COFILEA SRL UNINOMINALE

AI summary

A textile article, in form of a heating multilayer fabric, including a textile heating layer associated with an electrical resistance adapted to be powered with an electric current for generating heat, and a reflective layer arranged adjacent to the heating layer to receive and reflect to a front side of the textile article the heat generated by the heating layer. The heating layer is made from a fabric that incorporates in its textile structure, as electrical resistance for heat generation, a yarn, in form of a serpentine, consisting of carbon fibers. The fabric of the heating layer is a special fabric made by a warp knitting machine or loom of the “crochet” type, using the yarn of carbon fibers as effect yarn to realize in the fabric the serpentine design of the electrical resistance intended to warm up.