U.S. patent application number 11/359646 was filed with the patent office on 2007-06-28 for 3-d fabric knitted stretch spacer material having molded domed patterns and method of making.
Invention is credited to Ronald M. Sytz.
Application Number | 20070144221 11/359646 |
Document ID | / |
Family ID | 38192035 |
Filed Date | 2007-06-28 |
United States Patent
Application |
20070144221 |
Kind Code |
A1 |
Sytz; Ronald M. |
June 28, 2007 |
3-D fabric knitted stretch spacer material having molded domed
patterns and method of making
Abstract
A fabric having a face surface and a back surface forming a
fabric plane, wherein the fabric is further processed to produce
spaced apart, repeated patterned domes extending out of the fabric
plane, the domes forming channels therebetween, producing a molded
formed 3-D fabric for evaporative cooling and/or insulation as well
as comfort, stretch, compression resistance, decreased weight, and
improved drape, softness, and/or conformability, depending upon the
yarn component and fabric properties.
Inventors: |
Sytz; Ronald M.; (Gastonia,
NC) |
Correspondence
Address: |
TRIANGLE PATENTS, P.L.L.C.
P.O. BOX 28539
RALEIGH
NC
27611-8539
US
|
Family ID: |
38192035 |
Appl. No.: |
11/359646 |
Filed: |
February 22, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60655617 |
Feb 23, 2005 |
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Current U.S.
Class: |
66/171 |
Current CPC
Class: |
D10B 2403/021 20130101;
D10B 2403/0331 20130101; D10B 2403/0212 20130101; D04B 1/18
20130101 |
Class at
Publication: |
066/171 |
International
Class: |
D04B 1/24 20060101
D04B001/24 |
Claims
1. A three-dimensional fabric for insulating and/or cooling
comprising a knitted spacer material, the material further
comprising: a face surface; a back surface in spaced apart relation
to the face surface; and a body portion constructed therebetween
forming a unitary, integrally constructed material within a first
material plane; wherein material is formed into patterned domed
shapes projecting out of the first material plane.
2. The three-dimensional fabric of claim 1, wherein the domed
shapes are provided in a predetermined, repeatable pattern.
3. The three-dimensional fabric of claim 1, wherein the domed
shapes are substantially uniform in shape.
4. The three-dimensional fabric of claim 1, wherein the domed
shapes vary in size and/or shape.
5. The three-dimensional fabric of claim 1, wherein the domed
shapes are circular or oval in shape.
6. The three-dimensional fabric of claim 1, wherein the domed
shapes are multi-sided in shape.
7. The three-dimensional fabric of claim 6, wherein the multi-sided
domed shapes have rounded edges.
8. The three-dimensional fabric of claim 6, wherein the multi-sided
domed shapes have sharp edges.
9. The three-dimensional fabric of claim 8, wherein the said
multi-sided domed shapes have cross-sectional shapes selected from
the group consisting of round, triangular, square, pentagonal ,
hexagonal, octagonal.
10. The three-dimensional fabric of claim 1, wherein the domed
shapes have non-symmetrical shapes.
11. The three-dimensional fabric of claim 1, wherein the domed
shapes produce channels therebetween.
12. The three-dimensional fabric of claim 1, wherein the domed
shapes protrude beyond the base fabric plane to a predetermined
height and angle.
13. The three-dimensional fabric of claim 12, wherein the height of
the domes is at least equivalent to or greater than the thickness
of the said fabric.
14. The three-dimensional fabric of claim 12, wherein the height of
the domes range between 2-20 times the thickness of the said
fabric.
15. The three-dimensional fabric of claim 1, wherein the fabric is
formed of three yarn systems: a first yarn system constituting the
said face surface; a second yarn system constituting the said back
surface; and a third yarn system constituting the said body
portion.
16. The three-dimensional fabric of claim 15, wherein at least one
of the said three yarn systems includes an elastomeric yarn
component.
17. The three-dimensional fabric of claim 15, wherein at least one
of the said three yarn systems includes a monofilament yarn
component.
18. The three-dimensional fabric of claim 15, wherein at least one
of the said three yarn systems includes a multifilament yarn
component.
19. The three-dimensional fabric of claim 15, wherein at least one
of the said three yarn systems includes a high strength yarn
component.
20. The three-dimensional fabric of claim 1, wherein the knitted
spacer material includes a monofilament core.
21. The three-dimensional fabric of claim 1, wherein the fabric
further comprises a secondary component, with said secondary
component being applied to the fabric as a lamination.
22. The three-dimensional fabric of claim 1, wherein the fabric
further comprises a secondary component, with said secondary
component being applied to the fabric as a coating.
23. The three-dimensional fabric of claim 22, wherein said
secondary component includes at least one moisture barrier.
24. The three-dimensional fabric of claim 22, wherein said
secondary component includes at least one phase change
material.
25. The three-dimensional fabric of claim 22, wherein said
secondary component includes at least one antimicrobial agent.
26. The three-dimensional fabric of claim 1, wherein the fabric
further comprises a secondary component, with said secondary
component being applied to the fabric as an infusion.
27. The three-dimensional fabric of claim 22, wherein said
secondary component includes at least one medication.
28. The three-dimensional fabric of claim 1, wherein a
sandwich-like material having a first side; and a spaced apart,
parallel second side is used as a base fabric, with said base
fabric being processed to produce the said three-dimensional fabric
having plurality of domed shapes.
29. The three-dimensional fabric of claim 28, wherein the said
sandwich-like material has a thickness ranging between about 2 mm
and about 10 mm prior to further processing to create the three
dimensional fabric.
30. The three-dimensional fabric of claim 28, wherein said
processing of the base fabric is provided via molding.
31. The three-dimensional fabric of claim 1, wherein said fabric is
used as a liner for protective garments and/or equipment.
32. The three-dimensional fabric of claim 1, wherein said fabric is
used as a liner for a garment.
33. The three-dimensional fabric of claim 1, wherein said fabric is
used as a liner for at least one part of a garment.
34. The three-dimensional fabric of claim 1, wherein the fabric is
used as a carrier for a secondary component including at least one
medication.
35. The three-dimensional fabric of claim 1, wherein at least one
wicking treatment is topically applied to the fabric or impregnated
in at least one of the yarn components.
36. A three-dimensional fabric, having a plurality of domed shapes,
comprising monofilament yarn components interconnected to form a
base fabric, which is thereafter formed into a 3-D dome-channeled
material for use as a garment or portion of a garment for providing
ventilation under protective equipment and/or clothing.
37. A method of manufacturing a three-dimensional fabric, formed
from a knitted spacer material, and having a plurality of domed
shapes, including the steps of: providing at least two yarn systems
for interconnecting via a knitting pattern, wherein at least one of
the at least two yarn systems includes a stretch yarn component and
at least one of the at least two yarn systems includes a
monofilament component; knitting the stretch yarn component
according to a predetermined pattern; providing corresponding male
and female mating mold components for forming three dimensional
domes in predetermined, repeating patterns in the fabric; inserting
the fabric between the molds; closing molds together with the
fabric there-between to produce dome shapes protruding from the
fabric plane; providing adequate, predetermined pressure and/or
temperature for setting the dome shapes in the fabric; and removing
the fabric from the molds after a predetermined dwell time.
38. The method of claim 37, wherein the said predetermined dwell
time ranges preferably between about 15 seconds and about 10
minutes, and more preferably between about 1 minute and about 5
minutes.
39. The method of claim 37, further including additional steps by
which the manufactured three dimensional fabric is cut and sewed to
form a garment, or at least a portion of a garment.
40. The method of claim 37, further including additional steps by
which a secondary component being applied to the fabric as a
lamination or a coating.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS(S)
[0001] This non-provisional utility patent application claims the
benefit of one or more prior filed applications; the present
application claims priority from U.S. provisional application Ser.
No. 60/655,617 which is incorporated herein by reference in its
entirety.
BACKGROUND OF THE INVENTION
[0002] (1) Field of the Invention
[0003] The present invention relates generally to textile products
and, more particularly, to a 3-D fabric with domed shaped formed
from a base "sandwich" material for providing cooling and/or
insulation and improved stretch, compression resistance, decreased
weight, and conformability and/or drape.
[0004] (2) Description of the Prior Art
[0005] U.S. Pat. No. 5,413,837 issued May 9, 1995 to Rock, et al.
for Three-dimensional knit fabric teaches a three-dimensional knit
or woven fabric that is permeable to water vapor but impermeable to
liquid water is provided, including a first fabric layer, a second
fabric layer and yarn interconnecting them, further including a
barrier layer adhered to the outside surfaces, and the fabric being
imperviously sealed.
[0006] U.S. Pat. No. 5,651,847 issued Jul. 29, 1997 to Loeffler for
Double-face circular knit teaches a double face circular knit
having two concentric lengths of knit web and an in-between spacer
structure, wherein spacer threads are textured coarse-filament
multifilament yarns, in combination with monofilament yarns.
[0007] U.S. Pat. No. 6,263,707 issued Jul. 24, 2001 to Miller, et
al. for Opaque heat-moldable circular knit support fabrics having
very high spandex content teaches a fabric and method including
opaque heat-moldable circular knit fabrics having relatively high
amounts of spandex material and other fibers to simultaneously
provide maximum support and comfort to a wearer, wherein the fabric
may be molded to the specifications of a wearer's body.
[0008] Prior art knitted spacer material commonly employs either
warp-knitting or circular knitting techniques to produce a fabric
having a predetermined thickness and bulk. However, the prior art
knitted spacer materials typically have a relatively high weight,
low stretch, and limited drape, since the fabric thickness and
compressibility are factors that are generally optimized for a
given application.
[0009] Thus, there remains a need for a 3-D fabric with domed
shapes formed from a knitted spacer material having increased
stretch and compression resistance, decreased weight, and improved
drape as well as cooling and/or insulating properties.
SUMMARY OF THE INVENTION
[0010] The present invention is directed to a knitted stretch
spacer material including the use of an elastomeric material such
as SPANDEX for stretch and compression resistance without
increasing weight, and improved conformability and/or drape. The
present invention is further directed to a knitted spacer material
further processed for particular applications, for example
including mold-based forming and heat setting to provide a fabric
having raised, shaped dimples or domes existing in a predetermined,
repeated pattern wherein the domes protrude significantly above the
fabric surface to provide a three-dimensional (3-D) channeled
fabric for evaporative cooling and/or insulation, and comfort, in
particular for applications as a layer of a garment, a liner
material, or an underlayer beneath protective clothing or articles,
such as, by way of example and not limitation, ballistic-protective
wear, fire-protective wear, chemical- or radiation-protective wear,
and the like. The present invention is still further directed to a
method for making a knitted spacer material having high stretch,
compression resistance, low weight, and improved drape or
conformability with further processing steps to create the domed
protrusions and garments or underlayers made therefrom.
[0011] Accordingly, one aspect of the present invention is to
provide a knitted spacer material including a "sandwich" fabric
having a face surface and a back surface in spaced apart relation
with a body or filler portion constructed therebetween, and wherein
the fabric is further processed to produce spaced apart, repeated
patterned domes that form channels therebetween, producing a molded
formed 3-D fabric. In embodiments where the fabric is used as a
garment or portion of a garment, the fabric may further include a
stretch yarn component for increased stretch and compression
resistance of the material.
[0012] Another aspect of the present invention is to provide a 3-D
dome-channeled knitted spacer material having different face and
back surfaces, further including a secondary component, which may
be applied as a coating, a lamination, and/or an infusion.
[0013] Still another aspect of the present invention is to provide
a method for producing 3-D dome-channeled "sandwich" material,
preferably formed from a knitted spacer material, in particular a
circular knitted spacer material.
[0014] Still another aspect of the present invention is to provide
a monofilament component fabric formed into a 3-D dome-channeled
material for use as a garment or portion of a garment, such as a
vest, for providing ventilation under protective equipment and/or
clothing.
[0015] These and other aspects of the present invention will become
apparent to those skilled in the art after a reading of the
following description of the preferred embodiment when considered
with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 illustrates an elevational view of the front of a
shirt formed with a dimpled fabric in one embodiment of the present
invention.
[0017] FIG. 2 illustrates an elevational view of the back of FIG.
1.
[0018] FIG. 3 illustrates a planar view of a portion of the shirt
of FIG. 1 with a close-up on the dimpled area.
[0019] FIG. 4 illustrates a closer view of FIG. 3.
[0020] FIG. 5 illustrates another closer view of FIG. 3.
[0021] FIG. 6 illustrates a planar view of an underside portion of
the shirt of FIG. 1.
[0022] FIG. 7 illustrates a closer view of FIG. 6.
[0023] FIG. 8 illustrates another closer view of FIG. 6.
[0024] FIG. 9 illustrates a perspective view of FIG. 6.
[0025] FIG. 10 illustrates a closer perspective view of FIG. 6.
[0026] FIG. 11 illustrates a perspective view of FIG. 6 (opposite
side from FIG. 10).
[0027] FIG. 12 is a side cross-sectional view of a spacer material
constructed according to the present invention.
[0028] FIG. 13 is a perspective view of an embodiment of the
present invention.
[0029] FIG. 14 is a knitting pattern for manufacturing an
embodiment of a spacer material constructed according to the
present invention.
[0030] FIG. 15 is a knitting pattern for manufacturing another
embodiment of a spacer material constructed according to the
present invention.
[0031] FIG. 16 illustrates a cross-sectional view of a knitted
stretch spacer material that is further processed via molding to
produce 3-D, spaced apart domes in a repeated pattern, extending
upward from one of either the face or back surface, produce a
raised, domed surface pattern.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] In the following description, like reference characters
designate like or corresponding parts throughout the several views.
Also in the following description, it is to be understood that such
terms as "forward," "rearward," "front," "back," "right," "left,"
"upwardly," "downwardly," and the like are words of convenience and
are not to be construed as limiting terms.
[0033] Referring now to the drawings in general, the illustrations
are for the purpose of describing a preferred embodiment of the
invention and are not intended to limit the invention thereto.
[0034] The present invention provides a fabric having a face
surface and a back surface forming a fabric plane, wherein the
fabric is further processed to produce spaced apart, repeated
patterned domes extending out of the fabric plane, the domes
forming channels therebetween, producing a molded formed 3-D fabric
for evaporative cooling and/or insulation as well as comfort,
stretch, compression resistance, decreased weight, and improved
drape, softness, and/or conformability, depending upon the yarn
component and fabric properties.
[0035] In one embodiment, the fabric is formed from a knitted
spacer material including a "sandwich" fabric having a face surface
and a back surface in spaced apart relation with a body or filler
portion constructed therebetween, and wherein the fabric is further
processed to produce spaced apart, repeated patterned domes that
form channels therebetween, producing a molded formed 3-D fabric,
and methods of making the same. In embodiments where the fabric is
used as a garment or portion of a garment, the fabric may further
include a stretch yarn component for increased stretch and
compression resistance of the material.
[0036] While FIGS. 1-2 illustrate a 3-D fabric used as a garment,
the sandwich construction is preferably not used as a complete or
full garment but as a partial garment such as an interior liner in
vest, garments, protective clothing, protective components,
etc.
[0037] FIGS. 1-11 illustrate 3-D fabric formed from predetermined,
repeating pattern of domed shapes formed by molding the fabric
between mating molds such that the domed shapes are formed as
projections from the basic plane of the fabric or material before
molding it. The domed shapes are provided in a predetermined,
repeatable pattern; the domed shapes may be uniform or may vary in
size and shape. The domed shapes may be selected from various
cross-sectional shapes as from a top view, from circular to
multi-sided, with rounded or sharper edges, including but not
limited to substantially triangular, square, pentagonal, hexagonal,
and so on, to 12-sided or more, as well as non-symmetrical shapes,
including but not limited to logos and other symbols. Symmetrical
shapes are preferred in most cases because they provide for uniform
load distribution across the dome plateau or peak. In any case, the
3-D domed shapes protrude or extend beyond the base fabric plane to
a predetermined height and angle for supporting the domed shape,
depending upon the application.
[0038] Furthermore, the 3-D fabric provides for "breathe-ability"
for cooling and/or insulating. Most significantly, the 3-D domed
shapes produce channels therebetween that allow for air flow for
evaporative cooling and/or insulating via the air traveling or
flowing in the channels and/or being trapped therebetween. Also,
the fabric body itself may include a predetermined permeability
depending upon the fabric construction, yarn density, yarn type,
and whether or not coatings, films, or other treatments are applied
(such as in the case of an all-monofilament base fabric body,
wherein the fabric air permeability is relatively high).
[0039] In preferred embodiments of the present invention, a
"sandwich" material having a first side and a spaced apart,
parallel second side is used as the base fabric prior to dome
formation via additional processing of the material. More
preferably, a knitted spacer material is used as the base fabric.
As best seen in FIG. 12, a knitted spacer material or base fabric,
generally referenced 10, is illustrated. The spacer material is
preferably a 3-dimensional (3-D) material itself, i.e., 3-D within
its own fabric plane, having an x-direction and y-direction forming
a fabric plane and a z-direction that is orthogonal to the other
directions, as shown in FIG. 13, i.e., forming a thickness (t) out
of the fabric plane. The material includes at least two yarn
systems, including a first yarn system and a second yarn system
that are interlaced with a third yarn system to form a knitted
material. FIG. 12 illustrates an embodiment according to the
present invention having three yarn systems, a first yarn system
12, a second yarn system 14, and a third yarn system 16 formed of
both monofilament and a multifilament or other yarn(s); the first
and second yarn systems preferably include an elastomeric yarn
component to provide stretch, such as SPANDEX. More specifically,
the knitted material has a face surface 18 (also shown in FIG. 13)
and a back surface 20 with a body portion 22 of the material formed
therebetween having a thickness measured between the two
surfaces.
[0040] In one embodiment of the present invention, special yarns
are selective used to provide enhanced functionality or added
features to the fabric. By way of example but not limitation, a
silver yarn may be used as part or all of one yarn system to
provide natural antibacterial qualities. Alternatively, high
strength yarns such as KEVLAR may be used for increased ballistic
or penetration-resistance. Any fiber may be used within the
"sandwich" fabric, depending upon the specific properties and
performance requirements and the application of the fabric.
[0041] The body portion includes the third yarn system providing a
compression resistant component substantially oriented in the
z-direction or thickness direction of the material; while this
component does extend in the x-direction and y-direction of the
material as well, its main function is to provide the material
properties in the z-direction or thickness by traversing between
the face and back surfaces of the material, forming a zig-zag
appearance when viewed from a side view as shown in FIG. 12.
Importantly, according to a preferred embodiment of the present
invention, at least this first yarn system includes an elastomeric
or a stretch component for increased stretch of the material in
both the x- and y-directions; preferably, the first and second yarn
systems in an embodiment as shown in FIGS. 12 and 13, include an
elastomeric or stretch yarn component. Surprisingly, the inclusion
of the elastomeric or stretch component introduces a substantially
increased compression resistance in the material in the z-direction
or thickness dimension. The elastomeric synthetic material, or
stretch component of the fabric preferably provides for an
increased stretch between about 25%.times.25% in the x- and
y-directions, respectively, to about 150%.times.200% in the x- and
y-directions, respectively, more preferably about 100%.times.120%
in the x- and y-directions, respectively. Surprisingly and
significantly, it is important to recognize that this inclusion of
the elastomeric or stretch yarn component in the first and second
yarn systems has allowed the reduction of yarn size, including
weight and stiffness, in the third yarn system which has allowed
the material according to the present invention to perform to the
desired objectives, as set forth in the foregoing, namely, to
provide a knitted stretch spacer material including the use of an
elastomeric or a stretch yarn component in predetermined levels to
provide for stretch and compression resistance, without increasing
weight, and improved drape and/or conformability that is further
processed, including lamination and/or coating, to provide a liquid
and vapor impermeable fabric, in particular for diving and wet suit
applications. The conformability is qualitatively measured as the
fabric's ability to change direction and shape to conform to a
user's body, in particular when the fabric is incorporated into a
garment or a portion of a garment or other bodily coverage. The
knitted spacer material according to the present invention is
formed with a face surface and a back surface in spaced apart
relation with a body portion constructed therebetween, wherein the
fabric further includes a stretch yarn component for increased
stretch and compression resistance of the material, including after
further processing, such as lamination and/or coating.
[0042] By way of specific design example, FIG. 16 illustrates a
cross-sectional view of a single dome in a knitted stretch spacer
material that is further processed via molding, specifically having
molding in a male/female mold to produce 3-D, spaced apart domes in
a repeated pattern, extending upward from one of either the face or
back surface, produce a raised, domed surface pattern as shown in
FIGS. 1-11.
[0043] In preferred embodiments, the knitted stretch spacer
material includes a monofilament core wherein the yarn is between
about 20 to about 400 denier, more preferably about 90 denier to
optimize knittability, comfort, and compression-resistance.
[0044] In one embodiment, the knitted stretch spacer material is
manufactured commercially by Beverly Knits, Inc. under the sample
number BK 3595 Heavy at 22 oz/sq. yd, or under the sample number BK
3571 Light--19 oz/sq yd, having a non-laminated weights of 21
oz/sq. yd and 16.7 oz/sq. yd, respectively.
[0045] Furthermore, the material according to one embodiment of the
present invention preferably has a thickness between about 2 mm to
about 10 mm, more preferably between about 4 mm and about 6 mm
prior to further processing to create the 3-D formed domed
channeled material, which increases the overall thickness of the
fabric by the dome height. Preferably, for garment, liner,
underlayer applications and the like, a range of dome heights may
be from at least equivalent to the fabric thickness, preferably
greater, and more preferably 2.times. to 20.times., which produces
larger channels for cooling and/or insulating and/or providing
additional body protection, such as penetration avoidance due to
the protruding shape, stand-off or dome height. The drape of the
fabric prior to molding or dome formation, as well as afterward, is
further characterized as being a conformability factor, i.e., the
capacity of the material or fabric to adapt to curvature, more
particularly, to change direction and shape to conform to a user's
body, in particular when the fabric is incorporated into a garment
or a portion of a garment or other bodily coverage. The sandwich
material or fabric described herein is uniquely suited to provide
comfort due to drape and surface qualities, as well as shape
retention, in particular substantial retention of the molded dome
shape and dimensions to preserve the air channeling functionality
when worn beneath other garments, specifically protective garments
having substantial weight. By contrast, significantly, lighter
weight, non-sandwich materials do not provide both benefits
simultaneously.
[0046] Preferably, the knitted spacer material is formed of
synthetic fibers in at least one of the yarn systems. Furthermore,
in a preferred embodiment of the present invention, monofilament is
used in at least one of the yarn systems, preferably in the third
yarn system. Importantly, the monofilament component provides for
additional improvement for compressibility and recovery as well as
reducing the overall weight of the material. The compressibility
and recovery properties of the present invention make it
well-suited for impact dispersion applications.
[0047] By contrast, a prior art material manufactured from a
warp-knit structure has significantly less stretch in the x- and
y-directions than the present invention, as well as being thinner
in the z-direction and being an overall heavier fabric per linear
square unit. Note however, that some warp knitted materials may be
manufactured at higher thicknesses, depending upon the
specifications and/or desired characteristics of the fabric in a
particular application, as is apparent to one of ordinary skill in
the art.
[0048] FIG. 13 illustrates another side view of an alternative
embodiment according to the present invention, having modified
properties, in particular affecting the stretch and/or compression
resistance and recovery of the material.
[0049] While preferably, the present invention is a circular knit
material, a warp-knit material may also be produced according to
the present invention as set forth hereinabove without departing
from the scope and spirit of the invention.
[0050] FIGS. 14 and 15 show knitting pattern examples used in
methods for manufacturing the knitted stretch spacer material
according to the present invention. In particular, FIG. 14 shows a
knitting pattern for a basic weft knit spacer material having a
predetermined density and number of ends per centimeter. The
elastomeric or stretch yarn component was added in this knitting
design to at least one of the yarn systems for providing increased
stretch and recovery properties in the finished material. Without
making any modifications to the yarn densities and/or knitting, the
overall material weight increased upon the addition of a stretch
yarn component. Surprisingly, and after much experimentation, the
knitting pattern shown in FIG. 15 was adapted to manufacture a
knitted stretch spacer material according to the present invention
wherein up to about a 50% reduction in monofilament yarns were
required to be employed in the yarn system(s) of that embodiment,
while providing a finished material having approximately equal or
improved stretch and recovery, drape and/or conformability, and
similar compression resistance to the embodiment shown in FIG. 14
while decreasing the overall material weight by comparison. The
number of courses per inch and wales per inch of the knitted
structure were higher and provided increased fabric density.
Therefore, the present invention provides a method of manufacturing
a knitted stretch spacer material by incorporating a stretch yarn
component and reducing the monofilament component(s) by up to about
50%, while retaining compression resistance, and providing improved
stretch and recovery, drape and/or conformability, and overall
decreasing the material weight. A method of manufacturing a knitted
spacer material including the steps of: providing at least two yarn
systems for interconnecting via a knitting pattern, wherein at
least one of the at least two yarn systems includes a stretch yarn
component and at least one of the at least two yarn systems
includes a monofilament component; knitting the stretch yarn
component according to the pattern, which permits the elimination
of up to about 50% of the monofilament weight of a standard,
non-stretch spacer fabric without a stretch yarn component, while
providing for comparable stretch and compression resistance,
decreased weight, and increased conformability of the spacer
material compared to the standard, non-stretch spacer fabric. Note
that, while most knitted structures provide for some
stretchability, non-stretch fabric, as used in the foregoing
description refers to a knitted fabric having stretch limited
substantially to that stretch provided by the knitting pattern
itself, and not due significantly to the yarn components used in
manufacturing the spacer material or fabric. Additional or further
steps of processing include: providing corresponding male and
female mating mold components for forming the 3-D domes in
predetermined, repeating patterns in the fabric; inserting the
fabric between the molds; closing molds together with the fabric
therebetween to produce dome shapes protruding from the fabric
plane; providing adequate, predetermined pressure and/or
temperature for setting the dome shapes in the fabric; removing the
fabric from the molds after a predetermined dwell time, which is
preferably between about 15 seconds to about 10 minutes, more
preferably between about 1 to about 5 minutes, wherein longer dwell
times typically correspond to stiffer and higher dome shapes.
Methods disclosed in the prior art applicable for forming the domed
shapes include, for example, U.S. Pat. Nos. 5,713,062; 6,007,898;
5,833,321; 5,851,930; 5,896,680; 5,882,322; 5,972,477; which are
used for forming knitted or woven fabrics made entirely of
monofilament yarns, all of which are incorporated herein by
reference in their entirety, being cited not as the present
invention but for providing enabling disclosure supporting the
present invention as set forth herein.
[0051] In another preferred embodiment, monofilament yarn
components are interconnected to form a fabric that is further
processed to create 3-D dome-channeled material for use as a
garment or portion of a garment, such as a vest, for providing
ventilation under protective equipment and/or clothing. Preferably,
the monofilament is at least about 100 denier monofilament to
provide sufficient stiffness and porosity for cooling and
ventilation via channels between the 3-D fabric domes as well as
through the plane of the fabric and domes directly, i.e., at
substantially perpendicular direction to the channels. Thus, the
fabric provides for breathability via fabric permeability as well
as via channels to allow for evaporative cooling, or passive
cooling. The fabric may be used as a liner for new garments and be
interconnected at seams or other predetermined locations so as to
provide a single garment, or as a liner that may be retrofit or
attached to existing garments. In the latter case, the lining may
be provided in the form of one or more panels that substantially
fit under sections or portions of the garment, but are not made to
exactly line or match the garment itself. These panels may be
removably attachable in predetermined locations to the garment, for
example by fasteners, hooks, buttons, hook-and-loop type fasteners,
and the like, and combinations thereof.
[0052] Additional steps may be included for coupling or connecting
(removably or permanently affixing) the fabric to a protective
device or component such as a vest or garment lining, or cutting
and sewing or otherwise connecting bonding the fabric segments to
form a garment or a partial garment.
[0053] Other embodiments may include liners for back-packs, or
other sporting equipment, such as protective guards or padding,
including but not limited to soccer shin guards, football
protective wear, helmets, knee pads, elbow pads, and the like.
[0054] Certain modifications and improvements will occur to those
skilled in the art upon a reading of the foregoing description. In
particular, the knitted spacer material may function as a carrier
or substrate, wherein additional processing provides additional
and/or supplemental functionality not inherently present in the
material itself. By way of example, the present invention may be
further processed, e.g., by lamination or coating the fabric, where
fabric permeability is not desirable or needed to be maximized.
Additionally or alternatively, the knitted spacer material may be
infused with another substance, such as a medication, for use as a
bandaging material capable of releasing a medication at the
location of its application, e.g., directly to a wound in a bandage
application. Certain coatings can be applied to this spacer fabric
to achieve different benefits and/or fabric characteristics or
properties. Films applied to either side for moisture barriers or
to enhance wicking. By way of example and not limitation, a phase
change material may be applied to provide thermal management
properties, such as temperature resistance, fire retardants,
antimicrobial coatings or yarns may be used to manage, control, or
limit bacterial growth. Seaming, sealing, or other edge processing,
e.g, by way of example and not limitation, overedge sealing,
ultrasonic or RF welding, or seaming, may also be advantageously
included in additional processing, depending upon the application
for the material.
[0055] Also, the 3-D fabric including a "sandwich" or spacer
material may further function in some applications as a carrier of
medicines like anti-clotting drugs etc. The fabric is capable of
incorporating antibacterial products like silver or other chemical
treatments. Also the fabric may have wicking treatments applied
either topical or impregnated into the yarns. Any yarns can be used
on either side including, aramid yarns like the commercially
available KEVLAR, NOMEX, and others, natural fibers like cotton,
wool, etc. man made fibers like polyester, nylon, polypropylene and
others. The middle "sandwich" yarn can be made of other fibers
also, nylon, polyester, polypropylene, all that can be formed with
temperature and pressure.
[0056] All modifications and improvements have been deleted herein
for the sake of conciseness and readability but are properly within
the scope of the present invention.
DESIGN EXAMPLE(S)
[0057] This section outlines a few design examples, not necessarily
optimized, but illustrative of what can be done for a knitted
spacer material according to the present invention and method of
manufacturing the same. These design examples include the
following:
Example 1
[0058] In this preferred embodiment of the knitted spacer material
as shown in FIG. 12 and having a knitting pattern shown in FIG. 14,
the material was formed using the following components:
[0059] In the first yarn system direction, a Polyester yarn type of
40 denier was used in combination with a 40 denier spandex yarn; in
the second yarn system, a Polyester yarn type of 40 denier was used
in combination with a 40 denier spandex yarn; in the third yarn
system, a Polyester yarn type of 177 denier monofilament was used
in combination with a 70 denier polyester yarn. The machine set up
included the following parameters: A double knit machine with a
dial height variance up to 250 thousands separation from the
cylinder, utilizing spandex feeder to plait spandex on the dial
only and cylinder only feeds. Requirements include facilities to
implement monofilament yarn into the knitting elements with
controlled measurement of amount to minimize tension and improve
knitting of monofilament yarn such that it does not poke thru the
face and back of finished product.
[0060] Further information relating to the sample includes:
Laminated One Side--BK 3595 Heavy--22 oz/sq. yd, BK 3571 Light--19
oz/sq yd.
Unlaminated BK 3595 Heavy--21 oz/sq yd, BK 3571 Light--16.7 oz/sq
yd.
[0061] Knits specs the Unlaminates at 22.9 and 18 oz respectively,
so we start from different baselines.
Summary: Beneficial low spacer weight material.
Elasticity/Modulus (prior to dome channel formation):
[0062] As a matter of comparison to baseline:
[0063] One Side BK 3595 Heavy--elasticity and modulus are in the
30% and 150% range, respectively, of original unlaminated
measurements. The original numbers were Desirable to Very Desirable
for elasticity and Desirable for modulus. One Side BK 3571
Light--elasticity and modulus are in the 50% and 200% range,
respectively, of original unlaminated measurements. The original
numbers were Desirable for elasticity and Very Desirable for
modulus.
Permeability
[0064] Water impermeability before and after bonding tests was Very
Desirable.
[0065] Surprisingly, the introduction of 10% SPANDEX yarn in the
yarn component system(s) required much experimentation with the
machine set-up, wherein a setting of 17% was required for the
material to be produced and reproduced consistently, providing the
following material properties:
[0066] By increasing the spandex percentages and reducing the yarn
sizes, the results created a fabric with the third yarn system in
an almost vertical plane. This is most important to achieve the
compression resistances of the require applications. This surprise
allowed the reduction of monofilament used in the fabric to be
decreased by almost 50%. The results thus produced fabrics of
preferred weight variations, stretches and thickness.
BK 3595 Light; 17% spandex; 18.00 ounces per square yard weight;
100% length.times.150% width stretch, 6 mm thick.
BK 3595 Heavy; 17% spandex 22 ounces per square yard weight; 120%
width.times.200% length stretch, 6 mm thick.
BK 3571 Light; 10% spandex; 18.00 ounces per square yard weight;
80% length.times.90% width stretch, 5 mm thick.
BK 3571 Heavy; 10% spandex 28 ounces per square yard weight; 90%
width.times.160% length stretch, 6 mm thick.
[0067] Certain modifications and improvements will occur to those
skilled in the art upon a reading of the foregoing description. All
modifications and improvements have been deleted herein for the
sake of conciseness and readability but are properly within the
scope of the following claims.
* * * * *