The present invention relates generally to improved electro-conductive materials or textiles used, among other things, as heating elements or sensors, and the process of making same. More specifically, the present invention relates to the provision of, and process of making, improved electrically conductive materials which are in sheet or web form.
Reference is made to U.S. Pat. No. 6,172,344 B1 issued Jan. 9, 2001 to Rix, Gordon and Gerrard (the “344 Patent”), relating to the composition and manufacture of certain types of electro-conductive textiles that can be used as heating element components. Background information related to electro-conductive textiles can be found in the “344 Patent. A variety of terms are used herein to refer to the electro-conductive textile, including ECT, carbonized fabric and electro-conductive material, and precursors thereof, including woven, non-woven and knitted material, cloth and the like. For purposes hereof, such terms may be collectively referred to as ECT. Thus, as the context requires, ECT refers to the final product, as well as the precursor products that become the final electro-conductive textile or material.
The present invention relates generally to the fabrication of electro-conductive materials or textiles, and the use thereof, among other things, as heating elements or sensors, or in a variety of applications.
The features of the present invention will be more clearly understood from consideration of the following description in connection with accompanying drawings in which:
While the manufacture and use of ECT has previously been disclosed in the '344 Patent, an improved ECT can be manufactured by using a novel process employing an alternate apparatus as disclosed herein. By using such improved process, ECT with enhanced levels of uniformity in electrical resistance can be achieved. Enhanced uniformity of electrical resistance leads to improved levels of uniformity of heat profile when an electrical potential is applied across the ECT. It is well known in the art that when a potential is applied across a resistive element, electrical energy is converted to heat energy. When a potential is applied across the improved ECT of the present invention, heat is disposed over the entire surface of the ECT substantially isotropically.
To better understand the advantages of, and significant improvements that, the present invention has over conventional ECT, reference to the method of making conventional ECT is provided below.
A conventional process of manufacturing ECT requires the pre-prepared woven material being first folded longitudinally to reduce the width sufficiently to allow entry into a carbonization oven. The folded cloth is then transported through the oven by means of a conveyor belt. To maintain progress and take up the cloth as it exits the oven, an arrangement of feed and collection rollers are located at the end of the oven. The cloth is effectively pulled through the oven. The rollers regulate the speed of the cloth through the oven. The cloth, during its horizontal passage through the oven, is in a relaxed state in the weft direction and in a restrained condition in the warp direction due to the action of the feed and collection rollers. In this method of manufacture, the still hot cloth is rolled upon exiting the oven. It is known in the art that restraint and relaxation of the cloth during the carbonization process affects the electrical resistance of the finished cloth. However, until the present invention, it has not been known how and to what degree relaxation and/or restraint impacts the isotropicity of electrical resistance of the finished cloth.
The cloth produced in the conventional manner billows or bags in the middle of the roll width, while the selvedge edge of the cloth remains taught. The line upon which the cloth is folded longitudinally prior to carbonization remains creased despite efforts to render flatness to the cloth. As a result, the electrical resistance levels of the cloth are of an endotropic nature. As a result, and as seen in the tables of
An improved process of processing the cloth that becomes the ECT overcomes the cited disadvantages of the conventional process. The improved manufacturing process involves the pre-preparation of sufficiently narrow woven material being transported through an oven in an unfolded and flat state. The carbonization chamber of the oven is arranged in a vertical plane. Entry to the oven is by means of a top feed roller that takes the cloth initially up to the top mouth of the oven and then controls the speed of the downward progress of the cloth in a vertical manner and in a completely relaxed and unrestrained condition. As the cloth exists the oven it is collected in a catch basket where it is allowed to settle and cool before being assembled onto rolls.
The cloth produced by the improved method lies flat and does not significantly billow or bag in the middle of the roll width. Furthermore the selvedge edge of the cloth is relaxed. The electrical resistance levels of cloth manufactured by this improved method are of an isotropic nature. As a result, and as seen in the sets of tables comprising
To illustrate more specifically the results of the improved process of making ECT of the present invention, the following parameters are provided. The specifications of the conventional ECT prior to carbonization are as follows: width, 84 inches; ends per inch, 30 nominal; picks per inch, 22 nominal; finished fabric weight, 270 g/m2 nominal. The specifications of the conventional ECT after carbonization are as follows: width, 67 inches nominal; finished Fabric weight 240 g/m2 nominal.
The specifications of the improved ECT prior to carbonization are as follows: width, 58 inches; ends per inch, 30 nominal; picks per inch, 22 nominal; finished fabric weight, 330 g/m2 nominal. The specifications of the improved ECT after carbonization are as follows: width, 48 inches; finished fabric weight 210 g/m2 nominal.
As can be seen, a degree of loss of length of cloth takes place due to the unrestrained passage of the cloth through the oven. However, the improved uniformity of electrical resistance compensates for the reduced cloth length.
Referring now to
For the active heating test, the heater pads were connected to a bench power supply TTi TSX 3510 and a 6 volt potential applied. The current draw was noted every 10° C. The electrical resistance of each heater pad was thereafter calculated using Ohms law. The heater pads under test were covered with 3 inch thick closed cell foam insulation to limit the effects of varying air currents.
Referring now to
The isothermal characteristic of the improved ECT improves the performance of all manufactured items that employ the improved ECT as a form of a heating element or sensor within their construction.
In one embodiment of the present invention, the carbonized material is then collected in a catch basket 305 at the lower end of the vertically arranged oven 303. After cooling, the carbonized material 302 is collected into rolls. However, there can be certain circumstances where the cloth is not collected into a catch basket to settle and cool but is allowed to drape down over transit rollers to cool and settle before being committed to final rolling onto tubes for shipment. This is done in a relaxed state. The improved ECT made by the foregoing process 300 can be used to develop heat uniformly across its surface by applying a potential difference across the carbonized material. Thus, the improved ECT can be used as a heating element of a heating system.
An electrical circuit, such as a circuit for generating a potential and sensing current can be used in conjunction with the circuit for applying and regulating a potential difference across the heating element. Such an electrical control circuit can be arranged to control the temperature of the heating element, and to derive a control signal from an electrical current passing through the heating element. Electrodes can be connected to the heating element at spaced locations enabling the application of the potential difference across the area of the carbonized material between the electrodes. The heating system incorporating the carbonized material can be configured in a variety of orientations. Such a heating element can have a protective layer on at least one side thereof. Further, the element can include a pair of opposite sides that further comprises a pair of protective layers, the protective layers each being applied to a respective one of the opposite sides. The protective layers can be arranged so as to cooperate with at least one edging strip to encapsulate the carbonized fabric heating element.
The circuit used to apply the potential difference can include at least two conductive bus bars. These bus bars, preferably, are sewn in place. Other methods of attachment, such as gluing can also be used. These bars can each comprise at least one of copper, electrically conductive metal foil, woven wire braid, woven wire strips, an electrically conductive plastics material, and conductive wires. The circuit used to regulate the voltage supplied or current drawn across the carbonized material hence can be used to control the temperature of the carbonized material or heating element.
In order to practice the improved process for producing an electrically conductive material with substantially isotropic resistive characteristics, a novel apparatus for implementing same is required. Such an apparatus for making an electrically conductive material comprises an oven with a carbonization chamber arranged in a vertical plane; a feed roller adapted to feed the material in a regulated manner to the upper end of the vertically arranged oven; the feed roller adapted to transport the material in an unfolded and flat state vertically through the carbonization chamber of the vertically arranged oven; and a catch basket at the lower end of the vertically arranged oven adapted to collect the carbonized material or cloth. Such an apparatus would be adapted to carbonize polymers, including those from the group consisting of polyacrilonitrile, rayon and viscose fabric. For example, but not as a limitation of the potential applications in which the ECT can be used, there are disclosed below a variety of items in which the improved ECT can be incorporated.
The improved ECT product of the present invention can be incorporated into a form of heated carrying bag used by seaborne rescue, ambulance, paramedic, accident and emergency crews. The heated bag could contain at least one bag of transfusible liquid and a sterile blood administration set for use in the transfusion blood, blood derivatives, saline, glucose or other tranfusible liquids. Such a heated bag incorporating the improved ECT could be powered by a battery pack. This battery pack can be contained in the base of the bag, when required for portable use, for example, at the scene of an accident. Alternatively, the heated bag incorporating the improved ECT can be powered from the electrical system of the transportation vehicle on its way to the accident scene. In such an embodiment, the ECT heating element is preferably arranged on the inner face of the back and/or sides of the heated bag. The heated bag could further have an easy open zip fastener or alternatively, a means of closure such as a hook and loop type closure system, allowing access to the heated contents. Furthermore, such a heated bag could incorporate, among other things, a reflective insulated lining for heat retention, a weatherproof flap, a rigid loop for transportation on the belt of a paramedic and a carry handle on the top and/or sides thereof.
In addition, the improved ECT product can be incorporated into, or used as a form of, a heated blanket to be used in lifeboats, and by coastguards, helicopter, air-sea rescue services, ambulance, paramedic and accident and emergency crews. Such a heated blanket could contain a heated section for warming a patient, for example, at the scene of an accident. The blanket further could have a waterproof outer surface manufactured from high visibility material and could be overlaid with light reflective strips. The heated section of such a blanket is powered by a battery pack contained in a carry pack that could be either hand carried or suspended beneath a gurney, for example, when being carried to the scene of the accident. Alternately, such a blanket could be powered from the electrical system of a transportation vehicle. Such a heated blanket would be stowed when not in use, in, for example, a high visibility transportation tube that could contain a secondary battery pack that pre-heats the blanket, for example, when en-route to the scene of the accident. The blanket could also be coupled with, or stored in a distress signaling device. Such a device can be configured as a telescopic tube that can be extended as a baton to summon help. Such a signaling system, in combination with the heated blanket, could be combined as a vehicle emergency kit.
The improved ECT product would also be useful in beds, mattresses, blankets, duvets, covers, and throws for bedding, cushions and pillows, for healthcare and domestic use. Furthermore, a heated wound dressing could benefit from the use or inclusion of a heating element constructed from the improved ECT. Many other diverse healthcare products would also benefit from the use of the improved ECT. These include heated bandages, heated plaster-casts for the treatment of broken limbs; heated wraps, splints, supports and belts used for the relief and treatment of muscular and skeletal pain and disorders. Additional uses include as a form of heated cover or wrap to be displaced over a patient during an operation or medical procedure. The blanket would have flap sections that could be moved and lifted to allow access by medical staff during medical procedures or operations. The blanket could be laminated within an anti-bacterial cover material to aid with sterilization issues.
The improved ECT product would also be useful in beds, blankets, covers for bedding, cushions and pillows. The improved ECT could also be incorporated into baby incubators, stretchers, gurneys and operating tables. Any medical device that would require or give the patient benefit from the application of heat, e.g., where heat is to be applied to or close to human tissue, could be improved by the employment of a heating element comprising the improved ECT.
Additional, less sophisticated products, would benefit from the use or incorporation of the present invention. These include articles of clothing, such as, but not limited to coats, jackets, vests, waistcoats, trousers, gloves, footwear and headgear. Such products are not limited to those that are worn by humans. The present invention could be incorporated into veterinary products such as wraps, blankets, rugs and jackets. The improved ECT of the present invention could also be used in molding tools and covers used in the composites industry and plastics forming industry where strong reliance on uniformity of heat is required. In addition, the improved ECT of the present invention can be used in covers, wraps and bags for thermally sensitive equipment such as diagnostic equipment, computers, cameras, navigational aids, similarly packages and containers used for the transportation of thermally sensitive products such as pharmaceutical products and medicines. There are a variety of uses for the improved ECT of the present invention in the automotive and vehicle manufacturing industry, including car seat heater systems, heated roof liners and door panels, heated bunks in recreational vehicles and in the sleeper section of semi-rig trailers.
There are a variety of uses and applications of the improved ECT of the present invention in the food preparation, delivery and service industry, such as heated shelves, trays, warmers and trolleys along with pizza bags. There are also a variety of uses of the improved ECT of the present invention in the construction and building industry where such improved ECT could be employed in and beneath concrete to impart warming and activation of color changing pigments and dyes used for decorative purposes. In addition, the improved ECT could be used in under floor heating systems and heated wall coverings, heated roof shingles for ice and snow thawing.
The improved ECT of the present invention can also be used in infrared and heat signature weaponry targeting devices where an even and uniform heat profile is required, such devices being used for both mobile tank and static artillery training purposes, and also to mimic the heat signature if equipment or personnel to act as a military decoy. Additionally, the improved ECT of the present invention can be used in airborne and seaborne devices for use in connection with equipment which is sensitive to discerning the heat signature of a shape or surface. For example, a target made of the improved ECT material could be shot at with artillery or ballistic fire and still function when pierced or perforated by the projectile.
The improved ECT of the present invention can also be used in conjunction with shape change materials and alloys as a thermal triggering stimulus to initiate change or to return said shape memory material or alloy to its original shape. For example, the improved ECT can be used in clothing to change its shape, look or feel thereof. In addition, it can be used in furniture that, through the application of heat to a part of its construction or surface, is adapted to be changed to an alternate and possibly more comfortable shape or position. In these type of applications of the improved ECT, the improved material could be laminated, encased or encapsulated within a variety of such shape memory materials.
The innovative teachings of the present invention are described with particular reference to the exemplary embodiments described herein. It should be understood and appreciated by those skilled in the art that the embodiments described herein provide only a few examples of the many advantageous uses and innovative teachings herein. Various alterations, modifications and substitutions can be made to the process of the disclosed invention, and the resultant product, without departing in any way from the spirit and scope of the invention.
This application is a continuation-in-part of U.S. patent application Ser. No. 10/494,852, filed Nov. 1, 2002, claiming a priority date of Nov. 6, 2001, entitled “Heated Wound Dressing”; U.S. patent application Ser. No. 10/289,500, filed Nov. 5, 2002, claiming a priority date of Nov. 6, 2001 entitled “Heated Transportation Box” and U.S. patent application Ser. No. 10/475,579, filed Apr. 12, 2004, claiming a priority date of Apr. 27, 2001, entitled “Electro-conductive Textile Sensor”, the entire contents of which are incorporated herein by this reference. The Applicant hereby claim the benefits of these pending patent applications under 35 U.S.C. Section 119(e).
Number | Date | Country | |
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Parent | 10494852 | Oct 2004 | US |
Child | 11024566 | Dec 2004 | US |