US20200032428A1 - Spacer fabric and use thereof - Google Patents
Spacer fabric and use thereof Download PDFInfo
- Publication number
- US20200032428A1 US20200032428A1 US16/519,666 US201916519666A US2020032428A1 US 20200032428 A1 US20200032428 A1 US 20200032428A1 US 201916519666 A US201916519666 A US 201916519666A US 2020032428 A1 US2020032428 A1 US 2020032428A1
- Authority
- US
- United States
- Prior art keywords
- spacer
- yarns
- spacer fabric
- wrapping
- cloth layers
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 125000006850 spacer group Chemical group 0.000 title claims abstract description 124
- 239000004744 fabric Substances 0.000 title claims abstract description 101
- 229910052751 metal Inorganic materials 0.000 claims abstract description 9
- 239000002184 metal Substances 0.000 claims abstract description 9
- 238000010276 construction Methods 0.000 claims abstract description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 9
- 229910052802 copper Inorganic materials 0.000 claims description 7
- 239000010949 copper Substances 0.000 claims description 7
- 238000000034 method Methods 0.000 claims description 5
- 239000011248 coating agent Substances 0.000 claims description 4
- 238000000576 coating method Methods 0.000 claims description 4
- 238000009940 knitting Methods 0.000 claims description 4
- 239000000463 material Substances 0.000 description 6
- 238000004519 manufacturing process Methods 0.000 description 4
- 241001669679 Eleotris Species 0.000 description 3
- 230000006835 compression Effects 0.000 description 3
- 238000007906 compression Methods 0.000 description 3
- 238000001816 cooling Methods 0.000 description 3
- 230000005611 electricity Effects 0.000 description 3
- 238000012546 transfer Methods 0.000 description 3
- 238000009423 ventilation Methods 0.000 description 3
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 238000004804 winding Methods 0.000 description 2
- 239000004952 Polyamide Substances 0.000 description 1
- -1 Polyethylene terephthalate Polymers 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000009970 fire resistant effect Effects 0.000 description 1
- 239000011888 foil Substances 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 229910000510 noble metal Inorganic materials 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920000139 polyethylene terephthalate Polymers 0.000 description 1
- 239000005020 polyethylene terephthalate Substances 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
- 239000004332 silver Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
Images
Classifications
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B21/14—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B1/14—Other fabrics or articles characterised primarily by the use of particular thread materials
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
- D02G3/04—Blended or other yarns or threads containing components made from different materials
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
- D02G3/12—Threads containing metallic filaments or strips
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
- D02G3/36—Cored or coated yarns or threads
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/44—Yarns or threads characterised by the purpose for which they are designed
- D02G3/441—Yarns or threads with antistatic, conductive or radiation-shielding properties
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2101/00—Inorganic fibres
- D10B2101/20—Metallic fibres
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2401/00—Physical properties
- D10B2401/04—Heat-responsive characteristics
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2401/00—Physical properties
- D10B2401/06—Load-responsive characteristics
- D10B2401/061—Load-responsive characteristics elastic
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2401/00—Physical properties
- D10B2401/16—Physical properties antistatic; conductive
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2403/00—Details of fabric structure established in the fabric forming process
- D10B2403/02—Cross-sectional features
- D10B2403/021—Lofty fabric with equidistantly spaced front and back plies, e.g. spacer fabrics
Definitions
- the present invention relates to a spacer fabric. More particularly this invention concerns a knitted spacer fabric and a use thereof.
- a typical spacer fabric comprises two usually substantially flat or planar cloth layers and spacer yarns that transversely bridge and interconnect the cloth layers. Some of the spacer yarns and optionally even all of the spacer yarns having a core made of a yarn and a spiral wrapping.
- Spacer fabrics and, in particular, knitted spacer fabrics are characterized by a light, air-permeable structure, with spacer fabrics generally having an elasticity in the transverse direction of their thickness as a result of spacer yarns that run between the two cloth layers.
- knitted spacer fabrics are often provided as a soft, elastic layer that enables air circulation in mattresses, upholstered furniture, garments, or shoes.
- a conventional knitted spacer fabric is known from DE 90 16 062.
- spacer fabrics and, in particular, knitted spacer fabrics are frequently also used as technical fabrics for highly specialized applications.
- knitted spacer fabrics are also used in the automotive industry, for example for climate-controlled seats under the seat covers, with knitted spacer fabrics allowing for good contour adjustment due to their cushioning properties and very good restorative behavior despite the overall low weight per unit area.
- Knitted spacer fabrics are also used for the interior lining of vehicles, and it is even possible to use them over air bags through the introduction of local tear lines.
- the possible applications of knitted spacer fabrics are not limited to the areas of ventilation and/or elastic support.
- a knitted spacer fabric for heating purposes in which conductive yarns of a flat knitted cloth layer are formed from a plastic multifilament yarn provided with a conductive coating.
- the multifilament yarn has the advantage that, despite the conductive and, in particular, metallic coating of the individual filaments, it still has relatively good flexibility, thus enabling processing in a knitting process.
- the conductive yarns are exposed in at least the flat knitted layer that is usually facing a user.
- spacer knitted fabric Another highly specialized application of a spacer knitted fabric is known from US 2008/20299854 that also discloses a spacer fabric with the above-described features.
- a spacer fabric with two cloth layers and spacer yarns connecting the cloth layers is described, the spacer yarns having a core that is made of a yarn and a helical wrapping around the core.
- the knitted spacer fabric is fire resistant to a certain extent. This property is achieved particularly by the fact that the core is enclosed and protected by the wrapping, for which purpose the wrapping is made of a sufficiently insulating material wound up tightly around its core yarn.
- Another object is the provision of such an improved spacer fabric that overcomes the above-given disadvantages, in particular that has a new functionality.
- Another object is a preferred use of such a spacer fabric.
- a spacer fabric has according to the invention two transversely spaced cloth layers.
- First spacer yarns bridge and transversely connect the cloth layers and are each formed by a core yarn and a helical wrapping made of metal or having a metallic layer.
- Second spacer yarns also bridge and transversely connect the cloth layers but are of different construction from the first yarns.
- a wrapping is thus provided in at least the first spacer yarns that is made of metal or at least has a metallic layer.
- a spacer fabric is thus provided that is electrically and thermally conductive between the two cloth layers transversely, i.e. in the direction of thickness.
- the spacer yarns are not provided with a continuous sheath, which would lead to substantial stiffening.
- the wrapping can also be selected such that the spacer yarns can still be processed easily during manufacturing of the spacer fabric, which is not the case with solid or stranded metallic wires.
- the core of the spacer yarns is formed by a yarn.
- the term “yarn” refers in this context to monofilaments, multifilaments, or threads.
- the core is especially preferably formed by a multifilament yarn that is substantially softer and more flexible than a monofilament yarn with the same fineness.
- the metallic or metal wrapping does not form a closed surface and is flexible, the metallic material stiffens the composite first yarns.
- the core is made of a multifilament yarn, even if poorer restorative properties are produced in terms of a compression hardness as compared to a monofilament yarns.
- the wrapping in order not to adversely affect the flexibility of the spacer yarns that are provided with the wrapping and, beyond that, in order to achieve good functional properties, is strip-shaped and has a width and a thickness with the ratio of the width to the thickness being at least 5:1.
- the wrapping can be separated in the form of a strip from a thin foil or another strip stock.
- a wire is provided that is flattened and thus formed into the flat strip.
- Such a reshaping of a round wire that is usually flat at first is also referred to as flattening.
- the wrapping can be made of copper or have a layer of copper in the interest of good thermal and/or electrical conductivity.
- copper is preferable to more noble metals such as gold or silver, but these materials and other metals can also be used in principle within the scope of the invention.
- a covering layer of tin provides protection from corrosion while not impairing the thermal and/or electrical conductivity.
- the spacer yarns provided with the wrapping retain a high degree of flexibility, because the successive helical turns can still be moved and, in particular, angled relative to one another.
- the wrapping covers between 30% and 95% of the core yarn on its lateral surface, particularly between 40% and 80%. This degree of coverage provides good flexibility on the one hand while also providing sufficient conductivity in terms of heat and/or electricity on the other hand.
- the effective length to be considered for electrical conduction and heat conduction is substantially greater than the length of the spacer yarn itself.
- the length of wrapping in the unwound or rectified state is between 1.5 and 4, preferably between 2 and 2.5 times greater than the length of the wrapped core yarn itself.
- the spacer fabric which is preferably embodied as a knitted spacer fabric, is surprisingly characterized by very good conductivity in terms of electricity and heat.
- the total thickness of the spacer fabric can be between 1 mm and 20 mm, preferably between 2 mm and 10 mm.
- the core which is preferably made of multifilament yarn, preferably has a fineness of between 50 dtex and 150 dtex.
- the wrapping preferably is a strip in order to be wound around the core in a helical manner with the smallest possible thickness.
- the wrapping preferably has a cross-sectional area of between 200 ⁇ m 2 and 10,000 ⁇ m 2 , especially preferably between 600 ⁇ m 2 and 40 ⁇ m 2 .
- the two flat cloth layers are not limited in their specific design.
- the flat cloth layers are made of polymeric yarns and are also preferably free of metal and thus electrically non-conductive and thermally insulating.
- a knitted spacer fabric different laying patterns are possible, and openings can also be provided in the cloth layers, each of which is formed by a plurality of stitches.
- the spacer yarns are integrated into the cloth layers so that they are exposed to or even protrude beyond the outer faces of the spacer fabric.
- the fact that the wrapping of the spacer yarns results in a certain stiffening can also be advantageously exploited, so that they are less strongly angled in the stitch formation.
- the first spacer yarns provided with the wrapping can be adjusted in the same way through suitable selection of the core on the one hand and of the wrapping on the other hand, that the first spacer yarns still have good processability but also have a certain strength and rigidity at the same time.
- both the first and the second spacer yarns can be provided with the wrapping in the manner described.
- the first spacer yarns have core yarns with helically wound wrapping, while a second portion of the spacer yarns is provided without wrapping.
- the proportion of the number of one of the spacer yarns to the total number of the first plus the second spacer yarns in a given area is typically between 10% and 90%, preferably between 30% and 70%.
- the second spacer yarns are especially preferably made of monofilament yarn in order to impart good elastic properties and good compression hardness to the spacer fabric. In the context of such an embodiment, a functional division then takes place between the first spacer yarns and the second spacer yarns.
- the spacer yarns can be deformed after they are wrapped in order to stabilize the spacer yarns provided with the winding to some extent.
- the yarns provided with the wrapping can be flattened between rolls prior to processing, i.e. particularly knitting, in which case the spacer yarns are given an approximately oval cross-sectional shape.
- the structure of the first spacer yarns is stabilized on the one hand and, on the other hand, the flexibility in the spacer fabric formed is reduced. In particular, this can prevent the spacer yarns from twisting or the wrapping from twisting relative to the core.
- the spacer fabric according to the invention can be provided in an especially advantageous manner as a heat-conduction layer, for best service as the preferred use with an electrical or electronic component.
- the knitted spacer fabric is characterized by a particularly light structure, but good heat transfer is possible in the transverse direction of thickness. It is also of particular advantage that the spacer fabric is elastic in the direction of thickness. For example, the spacer fabric can also be used in gaps and cracks in order to allow heat transfer there.
- Such an arrangement is advantageous particularly if electrical components are to be cooled in a housing.
- the spacer fabric can be used for heat transfer in such installation situations.
- an adhesive, a paste, or the like can be used on the cloth layers for better fixation and/or contacting, it being possible even then for thickness compensation or thickness adjustment to be performed by the spacer yarns.
- Different gap dimensions due to production-related fluctuations can be compensated for by the knitted spacer fabric in a particularly advantageous manner, and because of the low weight per unit area compared to known designs, weight savings can often also be achieved.
- the heat conduction is sufficient despite the overall airy structure.
- the electrical component can be a motor, a rechargeable battery module, an inverter, or the like.
- the electrical component can be a motor, a rechargeable battery module, an inverter, or the like.
- FIG. 1 is a perspective view of a piece of a knitted spacer fabric or fabric according to the invention
- FIG. 2 is a larger-scale view of a detail of the fabric of FIG. 1 ;
- FIG. 3 is a view of a short piece of a spacer yarn of the knitted spacer fabric according to FIG. 1 that is made of a yarn and a wrapping;
- FIGS. 4 a to 4 c shows method steps for forming the spacer yarn of this invention.
- FIG. 5 is a schematic view of a rechargeable battery module in a housing.
- FIG. 1 shows a spacer fabric in the form of a knitted spacer fabric with two cloth layers 1 and first and second spacer yarns 2 a and 2 b that extend transversely between the planes of and connect the layers 1 .
- FIG. 1 and the detail view of FIG. 2 show that the spacer yarns 2 a and 2 b are configured differently.
- the first spacer yarns 2 a each have a core 3 formed by a multifilament yarn and a helical wrapping 4 around the core 3 .
- the wrapping 4 is made of metal or has at least one metallic layer.
- the other spacer yarns 2 b are formed of polymeric monofilaments.
- the different spacer yarns 2 a and 2 b extend similarly between the two cloth layers 1 and also are of a similar thickness. While the metal-wrapped first spacer yarns 2 a ensure good conduction of heat and electricity, the second spacer yarns 2 b can provide the compression hardness and elastic recovery that are typical of a spacer fabric and particularly a knitted spacer fabric.
- the core 3 is a multifilament yarn with for example a fineness of 76 dtex.
- Polyethylene terephthalate is particularly suitable as the material, but other typical materials such as various polyolefins, polyamide, and the like can also be employed.
- the wrapping 4 has a strip-shaped configuration with a width b and a thickness d, the ratio of the width b to the thickness d being at least 5:1.
- the wrapping 4 is made of tinned copper, it being possible for an initially circular-section tinned copper wire to be flattened in order to form the strip-shaped configuration. Such a method step is shown by way of example in FIG. 4 a.
- the helical wrapping 4 also has the effect that the effective length for heat conduction or electrical conduction of the wrapping 4 is greater than the length of the core.
- the wrappings 4 In the unwound state, the wrappings 4 typically have a length that is 2 to 2.5 times greater than that of the respective core yarns 3 . Despite this increased path length, very good conduction of heat is observed overall.
- the wrapping can have a cross-sectional area of between 200 ⁇ m 2 and 10,000 ⁇ m 2 , particularly between 600 ⁇ m 2 and 4000 ⁇ m 2 .
- the multifilament yarn that is here provided as the core 3 can have 24 or 36 filaments, for example.
- FIG. 4 b indicates how the core 3 of multifilament yarn can be provided with the wrapping 4 .
- FIG. 4 c shows that the first spacer yarns 2 a can also be flattened to some extent before the knitting process to stabilize their cross-sectional shape and wrapping.
- the spacer fabric according to the invention is provided in an especially advantageous manner as a heat conduction layer, it being also optionally possible for ventilation to take place through it.
- the highly schematic representation of FIG. 5 shows the arrangement of a rechargeable battery module 5 in a housing 6 , with the spacer fabric forming an intermediate layer 7 between the outer surface of the module Sand the inner surface of the housing 6 .
- this spacer fabric as an intermediate layer 7 can be used to compensate for a remaining gap between the rechargeable battery module 5 and the housing 6 .
- the actual gap to be bridged can vary greatly due to manufacturing-related variations.
- the invention offers the advantage that the spacer fabric can be compressed when used as a heat conduction layer and also resets elastically to a certain extent. Such compensation is not possible with a thermally conductive paste or other compact media.
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- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Mechanical Engineering (AREA)
- Knitting Of Fabric (AREA)
- Resistance Heating (AREA)
- Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
- Woven Fabrics (AREA)
Abstract
A spacer fabric has two transversely spaced cloth layers. First spacer yarns bridge and transversely connect the cloth layers and are each formed by a core yarn and a helical wrapping made of metal or having a metallic layer. Second spacer yarns also bridge and transversely connect the cloth layers but are of different construction from the first yarns.
Description
- The present invention relates to a spacer fabric. More particularly this invention concerns a knitted spacer fabric and a use thereof.
- A typical spacer fabric comprises two usually substantially flat or planar cloth layers and spacer yarns that transversely bridge and interconnect the cloth layers. Some of the spacer yarns and optionally even all of the spacer yarns having a core made of a yarn and a spiral wrapping.
- Spacer fabrics and, in particular, knitted spacer fabrics are characterized by a light, air-permeable structure, with spacer fabrics generally having an elasticity in the transverse direction of their thickness as a result of spacer yarns that run between the two cloth layers. By virtue of these properties, knitted spacer fabrics are often provided as a soft, elastic layer that enables air circulation in mattresses, upholstered furniture, garments, or shoes. A conventional knitted spacer fabric is known from DE 90 16 062.
- In addition to such conventional applications in the consumer sector, spacer fabrics and, in particular, knitted spacer fabrics are frequently also used as technical fabrics for highly specialized applications. For instance, knitted spacer fabrics are also used in the automotive industry, for example for climate-controlled seats under the seat covers, with knitted spacer fabrics allowing for good contour adjustment due to their cushioning properties and very good restorative behavior despite the overall low weight per unit area. Knitted spacer fabrics are also used for the interior lining of vehicles, and it is even possible to use them over air bags through the introduction of local tear lines. The possible applications of knitted spacer fabrics are not limited to the areas of ventilation and/or elastic support. For instance, it is known from WO 2012/139142 to use knitted spacer fabrics for railway sleepers for connecting a concrete body to a sleeper pad, the knitted spacer fabric being embedded partially in the concrete body and in the sleeper pad during the manufacture of the sleeper body, thus enabling the especially reliable, permanent connection of these two elements.
- Another known application is the provision of a heating or sensor function, for which purpose wires and, in particular, stranded wires are incorporated into the fabric structure. Corresponding configurations are known from DE 19 903 070, DE 10 2008 034 937, and DE 10 2009 013 250.
- According to DE 10 2015 114 778, a knitted spacer fabric is proposed for heating purposes in which conductive yarns of a flat knitted cloth layer are formed from a plastic multifilament yarn provided with a conductive coating. The multifilament yarn has the advantage that, despite the conductive and, in particular, metallic coating of the individual filaments, it still has relatively good flexibility, thus enabling processing in a knitting process. The conductive yarns are exposed in at least the flat knitted layer that is usually facing a user.
- Another highly specialized application of a spacer knitted fabric is known from US 2008/20299854 that also discloses a spacer fabric with the above-described features. A spacer fabric with two cloth layers and spacer yarns connecting the cloth layers is described, the spacer yarns having a core that is made of a yarn and a helical wrapping around the core. The knitted spacer fabric is fire resistant to a certain extent. This property is achieved particularly by the fact that the core is enclosed and protected by the wrapping, for which purpose the wrapping is made of a sufficiently insulating material wound up tightly around its core yarn.
- It is therefore an object of the present invention to provide an improved spacer fabric.
- Another object is the provision of such an improved spacer fabric that overcomes the above-given disadvantages, in particular that has a new functionality.
- Another object is a preferred use of such a spacer fabric.
- A spacer fabric has according to the invention two transversely spaced cloth layers. First spacer yarns bridge and transversely connect the cloth layers and are each formed by a core yarn and a helical wrapping made of metal or having a metallic layer. Second spacer yarns also bridge and transversely connect the cloth layers but are of different construction from the first yarns.
- In the context of the invention, a wrapping is thus provided in at least the first spacer yarns that is made of metal or at least has a metallic layer. A spacer fabric is thus provided that is electrically and thermally conductive between the two cloth layers transversely, i.e. in the direction of thickness. However, the spacer yarns are not provided with a continuous sheath, which would lead to substantial stiffening. In particular, the wrapping can also be selected such that the spacer yarns can still be processed easily during manufacturing of the spacer fabric, which is not the case with solid or stranded metallic wires. The core of the spacer yarns is formed by a yarn. In keeping with its general meaning, the term “yarn” refers in this context to monofilaments, multifilaments, or threads.
- However, the core is especially preferably formed by a multifilament yarn that is substantially softer and more flexible than a monofilament yarn with the same fineness. Although the metallic or metal wrapping does not form a closed surface and is flexible, the metallic material stiffens the composite first yarns. Particularly in this context, it can be advantageous if the core is made of a multifilament yarn, even if poorer restorative properties are produced in terms of a compression hardness as compared to a monofilament yarns.
- According to a preferred embodiment of the invention, in order not to adversely affect the flexibility of the spacer yarns that are provided with the wrapping and, beyond that, in order to achieve good functional properties, the wrapping is strip-shaped and has a width and a thickness with the ratio of the width to the thickness being at least 5:1.
- Several embodiments of such a strip-shaped material are conceivable in principle. For example, the wrapping can be separated in the form of a strip from a thin foil or another strip stock. According to an especially preferred embodiment of the invention, however, a wire is provided that is flattened and thus formed into the flat strip. Such a reshaping of a round wire that is usually flat at first is also referred to as flattening.
- According to a preferred development of the invention, the wrapping can be made of copper or have a layer of copper in the interest of good thermal and/or electrical conductivity. Particularly in consideration of material costs, copper is preferable to more noble metals such as gold or silver, but these materials and other metals can also be used in principle within the scope of the invention.
- In order to achieve long-term protection in the case of a wrapping that consists substantially of copper, a covering layer of tin can be provided provides protection from corrosion while not impairing the thermal and/or electrical conductivity. In particular, it is also possible to flatten tin-plated copper wire as described above and thus to transform it into a strip-shaped material without removing or damaging the tin coating.
- As already explained above, the spacer yarns provided with the wrapping retain a high degree of flexibility, because the successive helical turns can still be moved and, in particular, angled relative to one another.
- According to a preferred embodiment of the invention, the wrapping covers between 30% and 95% of the core yarn on its lateral surface, particularly between 40% and 80%. This degree of coverage provides good flexibility on the one hand while also providing sufficient conductivity in terms of heat and/or electricity on the other hand.
- It is assumed that, in the usual embodiment of a core made of a basically nonconductive polymeric yarn, not only the electrical conduction but also the heat conduction takes place substantially via the wrapping, which is metallic or has at least one metallic layer.
- It should also be noted in this regard that, due to the helical shape of the winding, the effective length to be considered for electrical conduction and heat conduction is substantially greater than the length of the spacer yarn itself. With a typical width and coverage of the wrapping, the length of wrapping in the unwound or rectified state is between 1.5 and 4, preferably between 2 and 2.5 times greater than the length of the wrapped core yarn itself. The spacer fabric, which is preferably embodied as a knitted spacer fabric, is surprisingly characterized by very good conductivity in terms of electricity and heat.
- For example, the total thickness of the spacer fabric can be between 1 mm and 20 mm, preferably between 2 mm and 10 mm. The core, which is preferably made of multifilament yarn, preferably has a fineness of between 50 dtex and 150 dtex.
- As already explained above, the wrapping preferably is a strip in order to be wound around the core in a helical manner with the smallest possible thickness. In order to ensure sufficient stability on the one hand and good processability on the other hand, and in order to provide the desired conductive properties, the wrapping preferably has a cross-sectional area of between 200 μm2 and 10,000 μm2, especially preferably between 600 μm2 and 40 μm2.
- The two flat cloth layers are not limited in their specific design. Preferably, the flat cloth layers are made of polymeric yarns and are also preferably free of metal and thus electrically non-conductive and thermally insulating.
- In an embodiment as a knitted spacer fabric, different laying patterns are possible, and openings can also be provided in the cloth layers, each of which is formed by a plurality of stitches.
- Particularly if the cloth layers are made of nonconductive yarns according to a preferred embodiment of the invention, it can be advantageous if the spacer yarns are integrated into the cloth layers so that they are exposed to or even protrude beyond the outer faces of the spacer fabric. At the same time, the fact that the wrapping of the spacer yarns results in a certain stiffening can also be advantageously exploited, so that they are less strongly angled in the stitch formation. In particular, the first spacer yarns provided with the wrapping can be adjusted in the same way through suitable selection of the core on the one hand and of the wrapping on the other hand, that the first spacer yarns still have good processability but also have a certain strength and rigidity at the same time.
- In the context of the invention, both the first and the second spacer yarns can be provided with the wrapping in the manner described.
- According to an alternative, preferred embodiment of the invention, the first spacer yarns have core yarns with helically wound wrapping, while a second portion of the spacer yarns is provided without wrapping.
- The proportion of the number of one of the spacer yarns to the total number of the first plus the second spacer yarns in a given area is typically between 10% and 90%, preferably between 30% and 70%. The second spacer yarns are especially preferably made of monofilament yarn in order to impart good elastic properties and good compression hardness to the spacer fabric. In the context of such an embodiment, a functional division then takes place between the first spacer yarns and the second spacer yarns.
- According to an embodiment of the invention, the spacer yarns can be deformed after they are wrapped in order to stabilize the spacer yarns provided with the winding to some extent. As with the flattening of a wire to form the wrapping, the yarns provided with the wrapping can be flattened between rolls prior to processing, i.e. particularly knitting, in which case the spacer yarns are given an approximately oval cross-sectional shape. By virtue of such an oval, flatly pressed cross section, the structure of the first spacer yarns is stabilized on the one hand and, on the other hand, the flexibility in the spacer fabric formed is reduced. In particular, this can prevent the spacer yarns from twisting or the wrapping from twisting relative to the core.
- The spacer fabric according to the invention can be provided in an especially advantageous manner as a heat-conduction layer, for best service as the preferred use with an electrical or electronic component.
- The knitted spacer fabric is characterized by a particularly light structure, but good heat transfer is possible in the transverse direction of thickness. It is also of particular advantage that the spacer fabric is elastic in the direction of thickness. For example, the spacer fabric can also be used in gaps and cracks in order to allow heat transfer there.
- Such an arrangement is advantageous particularly if electrical components are to be cooled in a housing. For example, if rechargeable batteries, motors, and other electrical components are placed in a housing with an ohmic resistance, the spacer fabric can be used for heat transfer in such installation situations. Optionally, an adhesive, a paste, or the like can be used on the cloth layers for better fixation and/or contacting, it being possible even then for thickness compensation or thickness adjustment to be performed by the spacer yarns. Different gap dimensions due to production-related fluctuations can be compensated for by the knitted spacer fabric in a particularly advantageous manner, and because of the low weight per unit area compared to known designs, weight savings can often also be achieved. Especially for the described applications, the heat conduction is sufficient despite the overall airy structure.
- Finally, applications are also conceivable in which the cooling is improved even further through ventilation of the spacer fabric, so that a cooling by convection or a cooling air flow then also occurs in addition to the heat conduction via the thickness.
- One specific application in which the advantages described above are especially evident is for an electrical component fitted in a housing, in which case small gaps may remain due to assembly. The electrical component can be a motor, a rechargeable battery module, an inverter, or the like. In this context, it should also be noted that, particularly with regard to the storage of electric current for mobile applications such as electric vehicles or in connection with photovoltaic systems, increasing demand exists for corresponding electrical components, with weight minimization being desired particularly for mobile use.
- The above and other objects, features, and advantages will become more readily apparent from the following description, reference being made to the accompanying drawing in which:
-
FIG. 1 is a perspective view of a piece of a knitted spacer fabric or fabric according to the invention; -
FIG. 2 is a larger-scale view of a detail of the fabric ofFIG. 1 ; -
FIG. 3 is a view of a short piece of a spacer yarn of the knitted spacer fabric according toFIG. 1 that is made of a yarn and a wrapping; -
FIGS. 4a to 4c shows method steps for forming the spacer yarn of this invention; and -
FIG. 5 is a schematic view of a rechargeable battery module in a housing. -
FIG. 1 shows a spacer fabric in the form of a knitted spacer fabric with two cloth layers 1 and first and second spacer yarns 2 a and 2 b that extend transversely between the planes of and connect the layers 1.FIG. 1 and the detail view ofFIG. 2 show that the spacer yarns 2 a and 2 b are configured differently. The first spacer yarns 2 a each have acore 3 formed by a multifilament yarn and a helical wrapping 4 around thecore 3. The wrapping 4 is made of metal or has at least one metallic layer. - It can already be seen from the detailed view of
FIG. 2 that, if desired, good electrical conduction can also be achieved by the metallic wrapping 4 transversely, in the direction of thickness, the other spacer yarns 2 b are formed of polymeric monofilaments. - The different spacer yarns 2 a and 2 b extend similarly between the two cloth layers 1 and also are of a similar thickness. While the metal-wrapped first spacer yarns 2 a ensure good conduction of heat and electricity, the second spacer yarns 2 b can provide the compression hardness and elastic recovery that are typical of a spacer fabric and particularly a knitted spacer fabric.
- The exact configuration of the first spacer yarns 2 a provided with the sheath 4 can be seen from the sectional view of
FIG. 3 . In the illustrated embodiment, thecore 3 is a multifilament yarn with for example a fineness of 76 dtex. Polyethylene terephthalate is particularly suitable as the material, but other typical materials such as various polyolefins, polyamide, and the like can also be employed. - It can be seen from
FIG. 3 that the wrapping 4 has a strip-shaped configuration with a width b and a thickness d, the ratio of the width b to the thickness d being at least 5:1. In the illustrated embodiment, the wrapping 4 is made of tinned copper, it being possible for an initially circular-section tinned copper wire to be flattened in order to form the strip-shaped configuration. Such a method step is shown by way of example inFIG. 4 a. - It is also apparent from
FIGS. 2 and 3 that there is a gap between the successive turns of the wrapping 4, 30% and 95% of the core being covered. - The helical wrapping 4 also has the effect that the effective length for heat conduction or electrical conduction of the wrapping 4 is greater than the length of the core. In the unwound state, the wrappings 4 typically have a length that is 2 to 2.5 times greater than that of the
respective core yarns 3. Despite this increased path length, very good conduction of heat is observed overall. - For example, the wrapping can have a cross-sectional area of between 200 μm2 and 10,000 μm2, particularly between 600 μm2 and 4000 μm2. The multifilament yarn that is here provided as the
core 3 can have 24 or 36 filaments, for example. -
FIG. 4b indicates how thecore 3 of multifilament yarn can be provided with the wrapping 4. Finally,FIG. 4c shows that the first spacer yarns 2 a can also be flattened to some extent before the knitting process to stabilize their cross-sectional shape and wrapping. - The spacer fabric according to the invention is provided in an especially advantageous manner as a heat conduction layer, it being also optionally possible for ventilation to take place through it. In this context, the highly schematic representation of
FIG. 5 shows the arrangement of arechargeable battery module 5 in a housing 6, with the spacer fabric forming an intermediate layer 7 between the outer surface of the module Sand the inner surface of the housing 6. In particular, this spacer fabric as an intermediate layer 7 can be used to compensate for a remaining gap between therechargeable battery module 5 and the housing 6. It should also be noted that the actual gap to be bridged can vary greatly due to manufacturing-related variations. Particularly in this context, the invention offers the advantage that the spacer fabric can be compressed when used as a heat conduction layer and also resets elastically to a certain extent. Such compensation is not possible with a thermally conductive paste or other compact media.
Claims (17)
1. A spacer fabric comprising:
two transversely spaced cloth layers; and
first spacer yarns that bridge and transversely connect the cloth layers and that are each formed by a core yarn and a helical wrapping made of metal or having a metallic layer.
2. The spacer fabric defined in claim 1 , wherein the wrapping is formed of metallic strip having a width and a thickness, a ratio of the width to the thickness bing at least 5:1.
3. The spacer fabric defined in claim 2 , wherein the strip is flattened wire.
4. The spacer fabric defined in claim 3 , wherein the wire is of copper or has a coating of copper.
5. The spacer fabric defined in claim 2 , wherein the strip is wound helically around the core yarn and forms a plurality of spaced turns between which the yarn is exposed.
6. The spacer fabric defined in claim 5 , wherein the strip covers 30% to 95% of the core yarn.
7. The spacer fabric defined in claim 1 , further comprising:
second monofilament spacer yarns that also bridge and transversely connect the cloth layers but that are of different construction from the first yarns.
wherein the second spacer yarns are monofilaments.
8. The spacer fabric defined in claim 1 , wherein the core yarn is a multifilament yarn.
9. The spacer fabric defined in claim 1 , wherein the cloth layers and first and second spacer yarns are knitted.
10. The spacer fabric defined in claim 1 , wherein a total thickness of the spacer fabric is between 1 mm and 20 mm.
11. The spacer fabric defined in claim 1 , wherein the core yarn has a fineness between 50 dtex and 150 dtex.
12. The spacer fabric defined in claim 1 , wherein the wrapping has a cross-sectional area of between 200 μm2 and 10,000 μm2.
13. The spacer fabric defined in claim 1 , wherein the first spacer yarns have a cross-sectional shape that is not circular.
14. Use of the spacer fabric of claim 1 as a heat conduction layer.
15. The use defined in claim 14 , wherein the spacer fabric is connected to an electrical component.
16. The use defined in claim 14 , wherein the spacer fabric is in a gap between a housing wall and the electrical component.
17. A method comprising the steps of:
forming first yarns of a multifilament nonconductive core yarn wrapped helically by a conductive and flexible metal strip;
providing second monofilamentary yarns; and
knitting together the first and second yarns into a spacer fabric formed of two transversely spaced cloth layers largely formed of the second yarns and bridged by first spacer yarns formed by the first yarns and by second spacer yarns formed by the second yarns.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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DE102018118254.6A DE102018118254A1 (en) | 2018-07-27 | 2018-07-27 | Spacer textile and use of a spacer textile |
DE102018118254.6 | 2018-07-27 |
Publications (1)
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US20200032428A1 true US20200032428A1 (en) | 2020-01-30 |
Family
ID=69148704
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US16/519,666 Abandoned US20200032428A1 (en) | 2018-07-27 | 2019-07-23 | Spacer fabric and use thereof |
Country Status (3)
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US (1) | US20200032428A1 (en) |
CN (1) | CN110777476A (en) |
DE (1) | DE102018118254A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11242628B2 (en) * | 2018-08-28 | 2022-02-08 | Mueller Textil Gmbh | Spacer fabric |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN112267206B (en) * | 2020-10-27 | 2022-04-15 | 江南大学 | Preparation method of super-large-gauge warp-knitted spacer fabric, application of super-large-gauge warp-knitted spacer fabric and inflatable cushion |
Family Cites Families (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE9016062U1 (en) * | 1990-11-26 | 1991-02-14 | Müller Textil GmbH, 5276 Wiehl | Textile spacer fabric |
DE29722311U1 (en) * | 1997-12-17 | 1998-02-26 | Frenzelit-Werke GmbH & Co KG, 95460 Bad Berneck | Technical coarse yarns |
DE19903070A1 (en) * | 1999-01-27 | 2000-08-31 | Mueller Textil Gmbh | Spaced knitted vehicle seat upholstery fabric has one layer with high air permeability and layer with reduced air permeability incorporating electrically conductive threads for heating |
US6477865B1 (en) * | 1999-12-16 | 2002-11-12 | Asahi Doken Kabushiki Kaisha | Three-dimensional marquisette style knitted fabric |
DE102004023361A1 (en) * | 2004-05-12 | 2005-12-08 | W + R Gmbh | High strength yarn material, for use in protective gloves, is a core yarn with a metal core cladded with aramide fibers and an outer cladding of fibers for comfort against the skin |
DE102006006337A1 (en) * | 2006-02-11 | 2007-08-16 | Kümpers GmbH & Co. KG | Spatial textile component structure on high-strength threads, as well as methods for their production |
US20080299854A1 (en) * | 2007-06-01 | 2008-12-04 | Ssm Industries, Inc. | Flame Resistant Spacer Fabric |
DE102009013250B3 (en) * | 2009-03-14 | 2010-07-15 | Müller Textil GmbH | Knitted fabric section for use as heating insert of e.g. car seat, has single common, knitted-in connection conductor thread knitted between connecting sections along longitudinal side of fabric section and cut off in region of side |
CN201485574U (en) * | 2009-06-17 | 2010-05-26 | 许富标 | Conductive yarn capable of bearing dyeing, finishing and washing |
DE102010010524B4 (en) * | 2010-03-05 | 2013-11-07 | Müller Textil GmbH | Spacer textile, in particular spacer fabric |
AT510835B1 (en) * | 2011-04-15 | 2012-07-15 | Getzner Werkstoffe Holding Gmbh | TRACK THRESHOLD |
DE102015114778A1 (en) * | 2015-09-03 | 2017-03-09 | Müller Textil GmbH | Spacer knitted fabric, spacer knit section and heatable cladding element |
DE102016125881B3 (en) * | 2016-12-29 | 2018-03-29 | Müller Textil GmbH | Spacer fabric, composite material formed with the spacer fabric, and use of the composite material |
-
2018
- 2018-07-27 DE DE102018118254.6A patent/DE102018118254A1/en not_active Withdrawn
-
2019
- 2019-07-23 US US16/519,666 patent/US20200032428A1/en not_active Abandoned
- 2019-07-26 CN CN201910679355.0A patent/CN110777476A/en active Pending
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11242628B2 (en) * | 2018-08-28 | 2022-02-08 | Mueller Textil Gmbh | Spacer fabric |
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DE102018118254A1 (en) | 2020-01-30 |
CN110777476A (en) | 2020-02-11 |
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