Double-Layer Woven Heating Fabrics: Design and Structure Optimization, Thermal Modeling, and Implementation of an Intelligent Temperature Control System

The aim of this research is to present the optimal pattern structure of double-layer woven heating fabrics, to deliberately increase the heating efficiency of the fabric on one side and reduction of heating energy loss on the other side of the fabric. Besides, analysis was carried out to provide a thermal model for a more detailed examination of the performance of these textiles in terms of thermal characteristics. Moreover, implementation of an intelligent temperature control system was performed to steadily regulate the temperature, at a predetermined temperature, in various external environmental temperature conditions. To achieve this purpose, nine samples of double-layer woven fabrics made of polyester yarns, consisting of nickel–chromium element as a proportion of weft yarns, were designed and produced. The mentioned fabrics were different in terms of weave pattern, connecting stitch type, and element-thread ratio. Finally, the effect of various structural factors of these fabrics in terms of thermal insulation properties, the heat production, and also the transfer process, has been investigated and a thermal model is introduced and described. Also, an intelligent control system based on Arduino microcontroller was designed and optimized based on PID control logic, and the ability of the control system to adjust the temperature was examined. Finally, according to the analysis of the results, it was determined that the double-layer tubular fabric is the most appropriate sample to achieve the goals of this research. The finding is due to the complete separation of the two layers of fabric from each other, and as a result, significant air is trapped between the two layers of the fabric creating an insulation layer in between. Also, the presented thermal model had acceptable results compared to the experimental data, and the control system was successful in controlling the textile temperature in different conditions.