CA1234597A - Electrical devices comprising ptc elements - Google Patents

Abstract

ABRIDGEMENT

A laminar electrical heater in which at least one of the electrodes is in the form of an elongate element forming part of a fabric and which comprises a PTC element, e.g. of a conductive polymer, to render the heater self-regulating.
Preferably the heater is prepared by weaving together (a) a first elongate element comprising a first electrode and a layer of PTC conductive polymer surrounding that electrode, and (b) a second elongate element comprising a second electrode. The resulting fabric can if desired be lami-nated to a sheet of a ZTC conductive polymer. A shrinkable fabric heater can be made by incorporating a heat-shrinkable non-conductive filament into the fabric, perpendicular to both electrodes, and is useful for example for enclosing splices in telephone cables.

Description

~3~ 7 BACXGROUND OF THE INVENTION

Field of_the Invention This invention relates to fabrics having useful electrical properties.

Introduction to the Invention Compositions which have a positive temperature coefficient of resistance (nPTC compositions") are known. They can be composed of ceramic material, eg. a doped barium titanate, or a conductive polymer material eg. a dispersion of carbon black or other particulate conductive filler in a crystalline polymer. The term PTC is generally used (and is so used in this specifi-cation) to denote a composition whose resistivity pre-ferably increases by a factor of at least 2.5 over a temperature range of 14C or by a factor of at least 10 over a temperature range of 100C, and preferabIy both.
The term switching temperature (or Ts) is generally used ~and is so used in this specification) to denote the temperature at which a sharp increase in resistivity takes place, as more precisely defined in U.S. Patent No. 4,237,441. Materials, in particular conductive polymer compositions, which exhibit zero temperature coefficient~(ZTC) behavior are also known~ In electri-cal devices which contain a PTC element and a ZTC ele-ment, the term ZTC is generally u~ed (and is so used inthis specification) to denote an element which does not : ~ :
exhibit PTC behavior at temperature below the Ts of the PTC element; thus the ZTC eLement can have a resist1vity : ~
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~ ' ' ' , ~3a~s~7 MPo85 9 which increases relatively slowly, or which is substan-tially constant, or which decreases slowly, at tempera-tures below the Ts of the PTC element. Materials, in particular conductive polymer compositions, which exhi-bit negative temperature coef~icient (NTC) behavior are also known. For further details of conductive polymer compositions and devices comprising them, reference may be made for e~ample to U.S. Patents Nos. 2,952,761,

2,978,665, 3,243,753, 3,351,882, 3,571,777, 3,757,086,

3,793,716, 3,823,217, 3,858,144, 3,861,029, 4,017,715,

4,072,848, 4,085,286, 4,117,312, 4,177,376, 4,177,446, 4,188,276, 4,237,441, 4,238,812, 4,242,573, 4,246,468, 4,250,~00, 4,255,698, 4,242,573, 4,271,350, 4,272,471, 4,276,466, 4,304,987, 4,309,596, 4,309,597, 4,314,230, 4,315,237, 4,318,881, 4,330,704, 4,334,351, 4,352,083, 4,361,799, 4,388,607, 4,398,084, 4,413,301, 4,425,397, 4,426,,339, 4,426,633, 4,427,877, 4,435,639, 4,429,216 and 4,442,139, J. Applied Polymer Science 19, 813-815 (1975), ~lason and Xubat; Polymer Engineering and Science 18, 649-653 (1978), Narkis et al; German OLS
Nos. 2,634,999, 732,792, 2,746,602, and 2,821,799; and European published patent application Nos. 38,713, 38,714, 38,718, 63,440, 67,679, 68,688, 74,281, 87,8~4, 92,406, 96,492, 84,302,717.8, 84,301,650.2 and the European application$ corresponding to ~anadian Serial Nos.
~67,265 and 463,796.

SUMMARY OF THE INVENTI N

There are serious limitations in the known tech-niques for making electrical devices which contain PTC
and/or ZTC elements composed of ceramic or conductive polymer materials. Ceramic materials are brittle and .
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are difficul~ to shape, particularly when large or complex shapes are needed. Conductive polymers can be manufactured in a wider variety of shapes, but espe-cially with PTC materials, close control is needed to ensure adequate uniformity; it is yet more difficult, if not impossible, to produce a predetermined variation in properties in different parts of an article. In addi~
tion, the physical strength of laminar conductive polymer devices is often less than is desirable. When a heat-shrinkable PTC conductive polymer article is required, there is the difficulty that when a PTC con-ductive polymer sheet is rendered heat-shrinkable (by stretching the cross-linked sheet above its melting point and then cooling it in the stretched state), the PTC of the heat-shrinkable sheet is often substantially smaller than that of the original sheet; this limits the stretch ratio that can be employed and, therefore, the available recovery.

We have now discovered that improved PTC devices ~ can be prepared by incorporating at least one of the electrodes into a fabric. Thus in one aspect, the invention provides a fabric which is suitable for use as an electrical heater and which comprises an ordered array of interlaced elongate elements, said fabric comprising (1) a first elongate electrode which forms at least part of one of said interlaced elongate elements; (2) a second electrode; and (3) a PTC element through which current passes when the first and second electrodes are connected to a source of electrical power.
, Particularly useful devices can be prepared by making use of an ~longate element which comprises an `' :
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elongate electrode and a resistive element which electrically surrounds the electrode; this elongate element is converted into a fabric which can be incorporated into an electrical system or device. A
wide range of such elongate elements can be easily produced in a uniform manner, and through the use of known fabric-manufacturing techniques, such as weaving, knitting and braiding, they can be converted into fabrics which are completely uniform or which vary in a desired predictable way. Other elongate elements can be included ln the fabric to provide or enhance desired properties such as strength or heat-recoverability or other thermally induced response.

In a preferred embodiment, the invention provides an electrical device which comprises (1) a first elongate element which comprises (i) a first elongate electrode and (ii) a first PTC element, preferably an elongate PTC conductive polymer element;
~ and (2) a second electrode which is spaced apart from the first electrode;

the first and second electrodes being connectable to a source of electrical power to cause current to pass through the PTC element; and the first elongate element forming part of a fabric in which the first elongate element is interlaced with at least one other elongate element to form an ordered array of interlaced - , .
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~23~ MPO859 elongate elements. In one preferred embodiment o~ such devices, the PTC element ~which may be a single elongate PTC element or a plurality of discrete PTC elements spaced apart along the length of the electrode) electric-ally surrounds the first electrode, i.e. the device isso constructed and arranged that, when the electrodes are connected to a power source, substantially all the current passing between the electrodes passes through the PTC element, at least at some temperatures between room temperature and the equilibrium operating temperature of the device, and preferably at all temperatures. In another preferred embodiment, the device comprises a third electrical element, preferably a ZTC conductive polymer element, through which current flows when the electrodes are connected to a power source; preferably substantially all the current passing between the electrodes passes through the third electrical element, at least at some temperatures between room temperature and the equilibrium operating temperatures of the device, and preferably at all temperatures.

Particularly useful devices are those which comprise an element, preferably a non-conductive element, which is thermally responsive and which is heated when current is passed through the device. Such devices can ~5 be recoverable, either as a result of passing current through the device or as a result of some other action.
For example, very useful heat-shrinkable articles comprise a~woven fabric comprising spaced apart first and second elongate electrodes running in one direction, and heat-shrinkable non-conductive elongate elements running in the other direction, the fabric being impregnated or coated with a heat-softenable ZTC

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~3~7 conductive polymer. When the article is powered, the heat generated by Joule heating causes the ZTC material to soften and the non-conductive elements to shrink, thus shrinking the fabric in the direction of the non-conductive elements and drawing the electrodes closer together.

The invention also includes processes in which a recoverable ~abric of the invention as described above, especiall~ one containing non-conductive heat-shrinkable filaments in the fabric, is used to cover a substrate, the process comprising:
~, (A) placing the fab~ic adjacent the substrate;

(B) recovering ~he fabric against the substrate, and (C) passing current between the electrodes to effect a desired change in the non-conductive element.

Step (C) can be carried out before, simultaneously ~lth, or after, step (B), and the recovery of the faDric can be effected by passing current between the eiectrodes or by some other means.

In another embodiment, the PTC element is a substantially continuous laminar element which is com-posed of a conductive polymer.

BRIEF DESCRIPTION OF THE DRAWING

The invention is illustrated in the accompanying drawing, in which the Figures are diagrammatic, partlal, .
:

~ ~ ~ 45 9~ MPO859 cross-sectional views of devices of the invention; in particular, Figure 1 is a side view of a heat-shrinkable device;

Figure 2 is a side view of the device of Figure 1 after it has been powered to effect shrinkage;

Figure 3 is a plan view of the device of Figure 1, Figure 4 is a side view of another heat-shrinkable device;

Figure 5 is a plan view of a device similar to that shown in Figure 1 and 2, but in which the electrodes are differently arranged and the ZTC
element coats but does not fill the fabric;

Figure 6 is a side view of ~another device similar to that shown in Figures 1 and 2 but in which one lS of the electrodes is woven into one fabric and the other electrode is woven into another fabric, and the two fabrics are secured together by the ZTC
element7 Figure 7 i5 a side view of a device similar to that shown in Figure 1 in which only one of the electrodes~is coated with a PTC element; and Figure 8 is a side view of another device of the invention. : ~ :
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~3~5~7 DETAILED DESCRIPTION OF THE INVENTION

The invention will chiefly be described herein by reference to the preferred devices of the inven-tion, in which there are two (or more) electrodes, at least one of the electrodes being an elongate electrode forming part of an elongate element which (i) comprises the electrode and a PTC conductive polymer element electrically surrounding the electrode and tii) forms part of the fabric.
However, the invention includes similar devices in which some other type of PTC element electrically surrounds the electrode (provided of course that it permits conversion of the element into the fabric).
In addition~ the invention includes fabrics comprising at least one elongate element which comprises (a) an elongate metal element and (b) a conductive polymer element which substantially ; surrounds the elongate metal element~and which may be ZTC or NTC element, fox example such a fabric which further comprises another electrode which is electri-cally separated from the first electrode not only by the ZTC or NTC element but also by a PTC element, preferably a conductive polymer PTC element. It shouId be understood, therefore, that the following detailed description also applies, mutatis mutandi~, to such other embodiments of the invention.

In;the preferred devices of~the invention, at lea~t one of~the electrodes is an elongate electroder usually of metal,~e.g. copper or nickel-coated copper, for exampLe a solid or ~tranded wire, which i~ electriaally : :
surrounded by~a PTC conductive~polymer element. Usually the PTC element will~be melt-shaped,~ preferably melt-extruded, preferably so that it physlcally surrounds ::

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MP0~59 _g_ the electrode as a uniform coating throughout its length. However, other methods of formillg the PTC ele-ment, e.g. dip-coating, and other geometric arrange-m~nts, are possible. For example the PTC element can vary in thickness and/or resistivity radially and/or longitudinally. Alternatively, the PTC element can alternate radially and/or longitudinally with polymeric elements which are electrically insulating or which have a resistance which is much higher than the resistance of the PTC element at room temperature, so that at least when the device is at relatively low temperatures, substantially all the current between the electrodes passes through the PTC element (it is to be noted that the broad definition of the devices of the invention does not exclude the possibility that at temperatures close to and above the Ts of the PTC element, a substan-tial part of the current does not pass through the PTC
element). The PTC element can be in direct physical contact with the electrode or can be separated therefrom ~ by a layer of ZTC material, for example a low resisti-vity conductive polymer. The dimensions of the PTC ele-ment and the resistivity and other properties of the PTC
composition should be correlated with the other elements of the device, but those skilled in the art will have no ~5 difficulty, having regard to their own knowledge ~e.g.
in the documents referenced herein) and the disclosure herein, in selecting suitable PTC elements. Suitable polymers include polyethylene and other polyolefins;
copolymers of one or more olefins with one or more polar comonomers e.g. ethylene/vinyl acetate, ethylene/acrylic acid and ethylene/ethylacrylate copolymers; fluoropoly-mers, e.g. polyvinylidene fluoride and ethylene/tetra-fluoroethylene copolymers; and polyarylene polymers, ~23~5~'7 e.g. poly~ther ketones; and mixtures o~ such polymers with each other and/or with elastomers to improve their physical properties.

~The other electrode in the preferred devices is preferably another elongate electrode which forms part of the same fabric as the first elongate element (as is usually preferred) or part of a different fabric. The second electrode can be the same as or different from the first electrode. Electrical contact between the first and second electrodes can be achieved in any suitable way. For example, the second electrode can be in contact with the first PTC element; or it can be electrically surrounded by a second PTC element which has the same Ts as the first PTC element and is in physical contact with a third electrical element as described above; or it can be in direct physical contact with a third electrical element as described above. Alternatively the second electrode can be an elongate electrode which is not interlaced to form part ~ of a fabric, or it can be a laminar electrode, e.g. a metal foil, apertured metal, or vapor-deposited metal electrode.

The third electrical element, when present (as is preferred), preferably comprises a ZTC conductive polymer. It can be of uniform composition or can comprise diqcrete sub-elements; for example it may be desirable to coat an electrode or a PTC element sur-rounding an electrode with a first ZTC conductive polymer in order to provide imProved electrical and physicaI contact to a second ZTC conductive polymer.
The third electrical elemen~ can ~ill or bridge the ~.
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interstices of the fabric(s), thus providing a con-tinuous laminar element. Alternatively, the third electrical element can be coated onto the fabric(s) so that apertures remain in the fabric. In another embodiment, part tor all) of the third electrical element is provided by an elongate element which is interlaced with at least one other elongate element to form part of the fabric(s), with the remainder (if any) of the third element being coated on or other-wise united to the fabric to provide desired electri-cal contact between the elongate elements. The third electrical element can be thermally responsive, e.g.
heat-shrinkable. The dimensions of the third electrical element and the resistivity and other pro-perties of the ZTC conductive polymers preferablyused for it should be correlated with the other ele-ments of the device, but those skilled in the art will have no difficulty, having regard to their own knowledge (e.g. in the documents referenced herein) and the disclosure herein, in selecting suitable ZTC
elements. When the device is recoverable, the ZTC
element preferably has low viscosity at the recovery temperature so that it impedes recovery as little as possible. Suitable polymers for the ZTC material include copolymers of ethylene with one or more polar copolymers, e.g. ethyl acrylate and vinyl acetate.

The first elongate element (and the other elongate elements) can be ormed into a fabric by any method which results in an ordered array of interlaced elongate elements. Weaving is the preferred method, but knitting, braiding etc. can be used in suitable cases.
The density of the weave (or other form of interlacing) ...

~3~ 7 MPo85 9 can be selected in order to provide the desired power output or shrinkability (when the fabric incorporates shrinkable elements as described below) or other pro-perty. Similarly, the density of the weave can be varied from one area to another to provide a desired variation, egO of at least 10~ or at least 25~, in one or more properties from one discrete area (which may be, for example, at least 5~ or at least 15% of the total area) to another. Triaxial weaving can he employed.

In order to pass current through the device, the electrodes must of course be connected to a power source, which may be DC or AC, e.g. relatively low voltage, e.g. 12, 24 or 48 volts. The various com-ponents of the device must be selected with a view to the power source to be employed. When the electrodes are elongate electrodes, they may be powered from one end or from a number of points along their lengths; the former is easier to provide, but the latter results in more uniform power generation.

2~ The device may include, at least in selected areas thereof, a non-conductive element which provides desired properties, particularly a non-conductive element which is thermally responsive and which is heated when current is passed between the electrodes~ or a non-conductive element, e.g. of glass fibers, which provide stiffness or other desired physical properties. The non-conductive element can be, for example, a heat-recoverable, e.g. heat-shrinkable, element. Such heat-recoverable elements can for example be composed of an organic polymer (which can be cross-linked) or a memory metal alloy. Other useful thermally responsive .

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members include a layer of a hot melt adhesive or a mastic; a thermochromic paint; or a component which foams when heated. The non-conductive element can be an elongate element which forms part of the fabric(s) incorporating the elongate electrode(s), e.g. a con-tinuous monofilament or multifilament yarn or a staple ~iber yarn. Suitable heat-shrinkable elements can be composed of, for example, a polyolefin, e.g. high, medium or low density polyethylene; a fluoropolymer, e.g. polyvinylidene fluoride; a polyester, e.g. poly-ethylene terephthalate or poly butylene terephthalate;
or a polyamide, e.g. Nylon 6, Nylon 6~6, Nylon 6, 12, Nylon 11 or Nylon 12. The element is preferably capable of unrestrained recovery to less than 50%, preferably less than 35~, especially less than 25% of its stretched dimension.

An especially preferred embodiment of the invention is a heat-shrinkable device which is useful, for example, for protecting ~oints between elongate sub-strates such as telephone cables, and which comprises:

(1) a first elongate electrode which comprises (i) a first elongate electrode composed of metal and (ii) a PTC element composed of a PTC
conductive polymer composition;

(2) a second elongate element which comprises a second elongate electrode composed of a metal;

(3) a heat-shrinkable elongate element which shrinks when heated to a temperature TShrink and which is composed of an electrically insulating polymeric composition;

said first, second and heat-shrinkable elongate elements having been woven together to form a fabric; and ~4) a ZTC electrical element which is composed of a ZTC conductive polymer composition;

the first and second electrodes being connectable to a source of electrical power to cause current to flow through the ZTC element and to cause shrinkage of the heat-shrinkable element, and the PTC element being positioned so that, when the electrodes are connected to a power source, suhstantially all the current passing between the electrodes passes through the PTC element.

The first and second elements generally run in one direction in the fabric (which may be the warp or the weft, depending on the ease of weaving), with the heat-shrinkable element running at right angles thereto. Thisenables the first and second elements to accommodate to shrinkage of the heat-shrinkable element by moving closer together, without longitudinal shrinkage.

The first and second elements can be powered from one end, in which case they will normally have a serpentine shape. Alternatively the fabric can be woven so that the electrode is or can be exposed at regular inter~a1s along th~ fabric, g each time it `
': -L5~7 changes direction, thus permitting the exposed ends to be bussed together by some bussing means which permits the desired shrinkage to take place. Generally, the exposed ends of the first electrodes will be ioined

5 together along one edge of the fabric and the exposed ends of the second electrode will be joined together along the opposite edge of the fabric.

In these devices, it is important that the heat generated in the conductive polymer elements is sufficient to raise the heat-shrinkable elements to their shrinkage temperature. In order to ensure that there is adequate heating of the ZTC element before the PTC element shuts off, it is preferred that the resistance of the ZTC
element is greater than, preferably at least 1.2 times, the resistance of the PTC elementts~ at all temperatures between 0C and TShrink. When the ZTC element forms a continuous laminar element (as is usually preferred in order to protect the substrate against which the device is to be recovered), this usually means that the resistivitv of the ZTC composition is greater than, preferably at least twice, the resistivity of the PTC
composition at all temperatures between 0C and Tshrink.

In these devices, it is preferred that the PTC con-ductive polymer composition has a first resistivity and comprises a first polymeric component which con-tains at least 50~ by volume of a crystalline polymer having a fi~st melting point Tl, the ZTC conductive polymer composition comprises a polymeric component which contains at least 50% by vblume of a thermoplastic polymer having a softening point T2 and a resistivity .

~3~5~

e2; wherein Tl > Tshrink > T2, and ~2 ~ el at all temperatures between 0C and Tshrink-It is also preferred that (Tl-T2) is at least 30C, particularly at least 50C, and that (Tl~Tshrink) is at least 10C, preferably at least 20C. We have obtained good results when the polymer in the PTC com-position is polyvinylidene fluoride, the polymer in theZTC composition is a copolymer of ethylene, eg. an ethylene/ethyl acryIate polymer, and the heat-shrinkable element comprises polyethylene.
.

The thermal properties of the device and of the surroundings are important in determining the behavior of the device. Thus the device can comprise, or be used in conjunction with, a thermal element which helps to spread heat uniformly over the device, eg. a metal foil layer, or which reduces the rate at which heat is removed from the device, eg. a layer of tbermal insulation such as a foamed polymer layer.

Referring now to the drawingl Figure 1 is a partial cross-sectional side view of a device of the invention, showing electrodes l of one polarity, each surrounded by a PTC conductive polymer element 11, and parallel electrodes 2 0f~opposite polsrity, each surrounded by a PTC conductive polymer elsment 21. The electrodes are :

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~23459~ MP0859 woven into a fabric with heat-shrinkable non-conductive filaments 4 at right angles to the electrodes, and the fabric is impregnated or coated with ZTC conductive polymer element 3.

Figure 2 is a partial cross-sectional side view of the device of Figure 1 after it has been powered to cause sbrinkage of the filaments 4 and softening of the ZTC
element 3.

Figure 3 is a partial cross-sectional plan view of a device as shown in Figure 1. The electrodes 1 are connected at one end to a bus bar connector 12 which runs along one edge of the fabric and does not prevent shrinkage of ~he filaments 4 when they are heated.
Similarly the electrodes 2 are connected at one end to a bus bar connector 22 which runs along the opposite edge of the fabric and does not prevent shrinkage of the filaments 4 when they are heated. The ZTC element 3 completely fills the interstices of the fabric.

Figure 4 is similar to Figure 1 and shows the same elements 1, ~, 3, 4, 11 and 21, and in addition shows elongate elements 6 which are woven into the fabric parallel to the PTC elements and are composed of a hot melt adhesive 15 which melts at the shrinkage tempera-ture of the filaments 4. Also shown in Figure 4 is an electrically insulating polymeric backing 7 which softens at the shrinkage temperature of the filaments 4.

Figure 5 is a partial cross-sectional plan view of another device of the invention which is similar to that shown in~Figures l and 3, but in which the electrodes `'"' - ' ; ' ~ ~ ., ~:34~97 follow a serpentine path and are powered from one end, and the ZTC element 4 coats the fabric but does not fill its interstices r leaving a plurality of voids 41.

Figure 6 is a partial cross-sectional side view of another device of the invention which is similar to that shown in Figures 1 and 2 except that the electrodes 1 are woven into one fabric with half of the heat-shrink-able filaments 4, while the electrodes 2 are woven into a second fabric with the other half of the heat-shrinkable filaments 4. The fabrics are secured to each other by the ZTC conductive polymer element.

Figure 7 is a partial cross-sectional side view of another device of the invention which is very similar to that shown in Figure 1 but in which there is no lS PTC coating around the electrodes 2.

Figure 8 is a partial cross-sectional side view of another device of the invention which comprises electrodes 1 and 2 embedded in a PTC element 11 to form a self-limiting strip heater preferably having an outer insulating jacket (not shown). The strip heater is woven into a fabric with heat-shrinkable Eilaments 4.

For further details of techniques for preparing fabrics and for using heat-shrinkable ~abric materials, and of heat-responsive materials which can be incorporated into or form part of fabrics, reference may be made to Canadian Patent Application Nos. 444,701; 444,695; 444,700; 444,698;
444,691; 444,697; 444,696 and 461,077 (Case Nos. RK 167, 176, 177, 178, 179, 181 and 205, and MPO790) filed by Raychem Limited on :~i 1~3~5~3~ MPO859 January 6, l983 and August 16, 1983 and Application No.
~48,547 filed by N.V. Raychem S.A. on March 1, 1983, Case No. BO89.

The invention is illustrated by the following Example.

EXAMPLE

A satin weave fabric was prepared using the following elongate elements:-1. a 24 AWG (diameter 0.064 cm) nickel-coated copper stranded wire conductor having a uniform melt-extruded coating thereon, about 0.008 inch (0.02 cm) thick, of a PTC
conductive polymer composition which had a resistivity of about 40 ohm.cm at 25C and over 500 ohm.cm at 130C, and which comprised carbon black dispersed in polyvinylidene fluoride, 2. a monofilament which is about 0.01 inch (0.025 cm) in diameter and which is composed of a polyamide hot melt adhesive; and 3. a high density polyethylene about 5 grams per denier monofilament which had been drawn down about 20 to 30 times immediately after extrusion, and which was therefore heat-shrinkable, with a TShrink Of about L28C~

The weft of the fabric was~composed of elements (1) and (2), there being three elements (2) between each of the elements (1), and the elements ~1) being 0.3 inch (0.76 cm) :

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, -20- ~ ~34597 MPO859 apart (center-to-center). The warp of the fabric was com-posed of elements (3) at a frequency of 72 filaments per inch.

The fabric was then irradiated to a dosage of 12-17 Mrad; thus cross-linking PTC conductive polymer and the polyethylene.

The irradiated fabric was laminated under heat and pressure to a 0.03 inch (0.076 cm) thick sheet of a conduc-tive polymer composition which had a resistivity of about 80 ohm.cm at 25C and about 200 ohm.cm ak 140C [i.e. it was ZTC compared to the PTC composition of element (1)], and which comprised carbon black dispersed in a very low crystallinity ethylene/ethyl acrylate copolymer. At the same time, the opposite face of the fabric was laminated to lS a 0.011 inch (0.028) thick layer of an insulating polymeric composition.

The resulting product had a cross-section similar to that shown in Figure 4. The electrodes followed a serpentine pattern similar to that shown in Figure 5.

When the electrodes were connected to a 36 volt DC
power source, the fabric heated to a temperature of about 130C, at which temperature the polyethylene filaments had reached their shrinkage temperature, and the hot-melt adhe-sive filaments and ZTC layer had softened; the fabric therefore shrank in the transverse direction to about 33%
of the original transverse dimension.

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Claims (12)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A fabric which is suitable for use as an electrical heater and which comprises ordered array of interlaced elongate elements, said fabric comprising: (1) a first elongate electrode which form at least part of one of said interlaced elongate ele-ments; (2) a second elongate electrode which forms at least part of one of said interlaced elongate elements; and (3) a PTC ele-ment which is in the form of a layer surrounding at least one of said electrodes and which is composed of a conductive polymer, and through which current passes when the first and second elec-trodes are connected to a source of electrical power.

2. A fabric according to claim 1 which further com-prises (4) a substantially continuous laminar element which is composed of a ZTC conductive polymer and through which current passes when the electrodes are connected to a source of electri-cal power.

3 A fabric according to Claim 1 or 2, wherein one of said interlaced elongate elements is an element which is electrically non-conductive and is thermally reponsive.

4. A fabric according to claim 1 which comprises (1) a first elongate element which comprises (i) a first elongate electrode composed of metal and (ii) a PTC element which electrically surrounds the first electrode and which is composed of a PTC conductive polymer composition;
(2) a second elongate element which comprises a second elongate electrode composed of a metal;

(3) a heat-shrinkable elongate element which shrinks when heated to a temperature TShrink and which is composed of an electrically insulating polymeric composition;

said first, second and heat-shrinkable elements forming a fabric prepared by weaving the first, second and heat-shrinkable elements together; and (4) a ZTC electrical element which is composed of a ZTC conductive polymer composition;

the first and second electrodes being connectable to a source of electrical power to cause current to flow through the ZTC element and to cause shrinkage of the heat-shrinkable element.

5. A fabric according to claim 4 wherein at all temperatures between 0°C and Tshrink of the heat-shrinkable element, the resistance of the ZTC element is greater than the resistance of the PTC element.

6. A fabric according to claim 4 wherein the PTC
conductive polymer composition has a first resistivity ?1 and comprises a first polymeric component which con-tains at least 50% by volume of a crystalline polymer having a melting point T1, the ZTC conductive polymer composition has a second resistivity ?2 comprises a polymeric component which contains at least 50% by volume of a thermoplastic polymer having a softening point T2; and T1 > Tshrink > T2, and ?2 > ?1 at all temperatures between 0°C and Tshrink.

7 A fabric according to claim 6 wherein (T1 - T2) is at least 30°C and (T1 - TShrink) is at least 10°C.

8. A fabric according to claim 6 or 7 wherein at all temperatures between 0°C and Tshrink of the heat-shrinkable element, the resistance of the ZTC element is greater than the resistance of the PTC element.

9. A fabric according to claim 6 wherein the polymer in the PTC composition is polyvinylidene fluoride, the polymer in the ZTC composition is a copolymer of ethy-lene, and the heat-shrinkable element comprises polyethylene.

10. A process for covering a substrate which comprises (A) placing adjacent the substrate a recoverable fabric which comprises (1) a first elongate element which comprises (i) a first elongate electrode and (ii) a PTC element surrounding the first electrode;
(2) a second elongate element which is interlaced with the first elongate ele-ment to form an ordered array of interlaced elongate elements;

(3) a second electrode;

the first and second electrodes being connectable to a power source to cause current to pass through the PTC element; and (4) an element which is thermally responsive and which is heated when current is passed between the electrodes;

(B) recovering the fabric against the substrate;
and (C) passing current between the electrodes to effect a desired change in the thermally responsive element.

11. A process according to claim lo wherein the fabric comprises a third electrical element through which current passes when the electrodes are connected to a power source.

12. A process according to claim lo wherein the ther-mally responsive element comprises a heat-shrinkable non-conductive element, a passing current between the electrodes causes shrinkage of the non-conductive ele-ment and shrinkage of the fabric.