U.S. patent application number 11/858594 was filed with the patent office on 2008-03-27 for knit elastic mesh loop pile fabric for orthopedic and other devices.
Invention is credited to George GEHRING.
Application Number | 20080072629 11/858594 |
Document ID | / |
Family ID | 39223459 |
Filed Date | 2008-03-27 |
United States Patent
Application |
20080072629 |
Kind Code |
A1 |
GEHRING; George |
March 27, 2008 |
KNIT ELASTIC MESH LOOP PILE FABRIC FOR ORTHOPEDIC AND OTHER
DEVICES
Abstract
An improved fabric for orthopedic devices is provided, being a
knitted fabric produced on either a warp or weft knit system and
utilizing a filament yarn selected from nylon and polyester as well
as spandex. The fabric enhances freedom of movement while
stimulating blood flow and muscle tone. The fabric has an
elasticity that enables closure of orthopedic and other devices by
placing the hook component of a Velcro (.RTM.) strip at any
convenient point rather than aligning it with the loop component of
the Velcro (.RTM.). The fabric is more convenient, faster and
easier for many incapacitated persons, enhancing wearing comfort.
Its mesh structure makes it more porous, which enhances the air
circulation and the moisture management in creating a cooling
effect on the wearer's skin and ready evaporation of perspiration,
while still providing therapeutic warmth without heat buildup.
Inventors: |
GEHRING; George; (Garden
City, NY) |
Correspondence
Address: |
GOTTLIEB RACKMAN & REISMAN PC
270 MADISON AVENUE, 8TH FLOOR
NEW YORK
NY
10016-0601
US
|
Family ID: |
39223459 |
Appl. No.: |
11/858594 |
Filed: |
September 20, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60847186 |
Sep 26, 2006 |
|
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|
60847305 |
Sep 26, 2006 |
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60847307 |
Sep 26, 2006 |
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Current U.S.
Class: |
66/202 ;
66/147 |
Current CPC
Class: |
D04B 21/18 20130101;
D10B 2403/0111 20130101; D10B 2501/0632 20130101; D04B 21/04
20130101; D04B 21/12 20130101 |
Class at
Publication: |
66/202 ;
66/147 |
International
Class: |
D04B 35/00 20060101
D04B035/00; D04B 39/00 20060101 D04B039/00 |
Claims
1. A knit fabric comprising: filament yarns selected from yarns of
the group consisting of nylon yarns and polyester yarns and present
in an amount between about 85 and 95% weight percent; spandex yarns
integrally knit with the filament yarns in an amount between about
5 and 15 weight percent; wherein the fabric has a mesh
construction; wherein the fabric has a loop pile construction along
one side thereof.
2. The fabric of claim 1, wherein the filament yarns comprise nylon
yarns.
3. The fabric of claim 1, wherein the spandex yarns have an
elongation at break of between about 300% and 700%.
4. The fabric of claim 1, wherein the mesh construction of the
fabric defines a plurality of openings, each having a pore size of
between about 1 and 3 mm. in diameter.
5. The fabric of claim 1, wherein said fabric is produced by a warp
knitting process.
6. The fabric of claim 1, wherein said loop pile construction is
produced by a process selected from the group consisting of
napping, overfeeding of the yarns, pressing off, and yarn
manipulation.
7. The fabric of claim 1, wherein said loop pile construction is
produced by a napping process.
8. The fabric of claim 1, wherein the filament yarns have a
tenacity of between about 4 and 7 grams/denier.
9. The fabric of claim 1, wherein the filament yarns have a
filament denier of between about 40 and 70.
10. The fabric of claim 9, wherein the number of filaments per yarn
of the filament yarns is between about 10 and 24.
11. The fabric of claim 9, wherein the spandex yarns have a denier
of between about 40 and 70.
12. The fabric of claim 3, wherein the fabric has a widthwise
stretch of between about 75% and 125% and a lengthwise stretch of
between about 25% and 60%.
13. The fabric of claim 1, wherein the mesh construction of the
fabric defines a plurality of openings having a widthwise mesh
count of between about 5 and 18 meshes/inch and lengthwise mesh
count of between about 4 and 6 meshes/inch.
14. The fabric of claim 10, wherein the spandex yarns have a denier
of between about 40 and 70.
15. The fabric of claim 13, wherein said plurality of openings each
has a size between about 1 and 3 mm. in diameter.
16. The fabric of claim 1, wherein: the filament yarns comprise
nylon yarns; the fabric is produced by warp knitting; the loop pile
construction is produced by a napping process.
17. The fabric of claim 16, wherein the mesh construction of the
fabric defines a plurality of openings having a widthwise mesh
count of between about 5 and 18 meshes/inch and lengthwise mesh
count of between about 4 and 6 meshes/inch.
18. The fabric of claim 16, wherein the nylon yarns have a tenacity
of between about 4 and 7 grams/denier.
19. The fabric of claim 17, wherein the filament yarns have a
filament denier of between about 40 and 70 and the spandex yarns
have a denier of between about 40 and 70.
20. The fabric of claim 19, wherein the spandex yarns have an
elongation at break of between about 300% and 700%.
21. A knit fabric comprising: filament yarns and spandex yarns
integrally knit with the filament yarns; wherein the fabric has a
mesh construction as well as a loop piles along one side
thereof.
22. A method for producing a fabric comprising: integrally knitting
filament yarns selected from the group consisting of nylon yarns
and polyester yarns with spandex yarns in order to produce a fabric
with a mesh construction; and generating a loop pile along one
surface of said fabric.
23. The method of claim 22, wherein said loop pile is generated by
a napping process.
Description
[0001] This application claims priority benefit of U.S. Provisional
Application No. 60/847,186 filed Sep. 26, 2006. The subject
application is also related to the following applications: [0002]
Fabric for Protection against Electric Arc Hazards [0003]
60/847,305 filed Sep. 26, 2006 U.S. patent application Ser. No.
______ filed ______, [0004] Under Body Armor Cooling Vest and
Fabric Thereof [0005] 60/847,307 filed Sep. 26, 2006 U.S. patent
application Ser. No. ______ filed ______, and [0006] Improved High
Performance Fire Resistant Fabrics and the Garments Made Therewith
[0007] 60/847,002 filed Sep. 25, 2006; U.S. patent application Ser.
No. ______ filed ______.
BACKGROUND OF THE INVENTION
[0008] The invention relates to a knit fabric, and, more
particularly, to an elastic knit fabric having a loop pile
construction.
[0009] Orthopedic devices such as braces, splints, supports,
orthodics, slings, bandaging, etc. are used to relieve discomfort,
pain, physical weakness for diverse conditions, ailments or
rehabilitative convalescence, such as osteoporosis, osteoarthritis,
tendonitis, sprains, bone fractures, chronic lower back pain,
compression fractures, degenerative disc disease, post operative
fusion, spinal tenosis (spinal narrowing), scoliosis (lateral
curvature of the spine), lumbar orthosis (spinal rectification) and
a number of others, each requiring a specialized aid or device.
These devices must be comfortable, lightweight, low profile,
patient friendly and suited for the daily living activities and
sedentary lifestyles for many afflicted persons.
[0010] Orthopedic devices consist essentially of several parts
including, but not limited to, a foam or rubber cushion, a fabric
covering, and supporting or adjustment straps, the latter of which
may carry buckles or Velcro (.RTM.) closure systems. A layer of
film, such as a non-woven or fibrous batting, may also be included
in some devices.
[0011] Velcro (.RTM.) closure systems are in many cases preferable
to others due to their simplicity, ease of use and faster
engagement or disengagement of component parts.
[0012] The cushioning material may be either neoprene rubber, a
non-woven material, a spacer fabric (a resilient 3-D fabric) or
some kind of foam. Neoprene, while cheap and in frequent use, has
poor air porosity, which leads to heat buildup, inducing
perspiration and discomfort.
[0013] There is a number of foam products available on the market
which are suitable for orthopedic applications. One of the better
known is the Rubberlite (.RTM.) product manufactured by the
Rubberlite Corp. of Huntington, W. Va. This foam is breathable,
stretchable, thermally formable and provides a controlled degree of
cushioning. This is an open celled polyurethane foam that can be
provided with an anti-microbial additive. It is, however,
disadvantageous since the foam does not sufficiently control the
amount of perspiration generated along a patient's skin. Such
perspiration must be removed from the skin and evaporated if a
feeling of clamminess is to be avoided. Also the Rubberlite foam is
less than desirable due to its tendency to break down and
disintegrate.
[0014] The components of orthopedic devices are held together and
in proper position on a patient's body by a system of engineered
designed straps engaged with each other through the action of
Velcro (.RTM.) type closures where the hook members of one strap
engage the loop pile of its mating strap. This requires mating of
both members.
[0015] The loop pile of the Velcro (.RTM.) closure may be either
woven or warp knit. The latter is softer and more pliable than the
woven variety. The warp knit product also has a significant amount
of useful give or extensibility. In most cases, the warp knit pile
is generated by a napping process, which raises the fabric floats
into a system of dense, erect loops. It is also possible to produce
such a pile without the process of napping by directly knitting the
surface loops. The same applies to circular knit fabrics of the
surface loop type:
[0016] In most cases, orthopedic devices are made with neoprene
rubber foam laminated to either a woven or knit fabric; they also
utilize Velcro (.RTM.) type closures for holding the devices in
place. Neoprene rubber foam carries the functional disadvantages
outlined above. Also, woven fabrics have low permeability to air
and do not conform well to the contours of a patient's body or
limbs.
[0017] Further, the Velcro (.RTM.) straps must be carefully aligned
and mated to effect a secure closure and correct fit of the
orthopedic device involved. Thus, the fabrics in current use have
limited flexibility and give, thereby constraining the freedom of
movement.
[0018] Accordingly, it would be desirable to provide an improved
fabric for use in orthopedic devices that overcomes the above
disadvantages.
SUMMARY OF THE INVENTION
[0019] In accordance with the invention, an improved fabric for
orthopedic devices is provided. The inventive fabric is a knitted
fabric produced on either a warp or weft knit system. The fabric is
knit utilizing a filament yarn selected from nylon and polyester as
well as spandex having an elongation at break of between about 300%
and 700%. The fabric is knit so as to have a mesh construction with
a pore size of between about 1 and 3 mm. in diameter. Importantly,
the inventive knit fabric has a loop pile construction generated
along one side thereof.
[0020] Other applications of the fabric according to the present
invention include backpack and footwear components working in
conjunction with the Velcro (.RTM.) closure system where the male
parts thereof engage the loop pile of the fabric to effect the
closure.
[0021] The improved fabric of the invention is advantageous since:
[0022] 1) the spandex content enhances the freedom of movement
while stimulating blood flow and muscle tone; [0023] 2) its
elasticity enables closure of orthopedic and other devices by
placing the hook component of the Velcro (.RTM.) strip at any
convenient point rather than aligning it with the loop component of
the Velcro (.RTM.); this is much more convenient, faster and easier
for many incapacitated persons and also enhances the wearing
comfort; and [0024] 3) the mesh structure makes it more porous,
which enhances the air circulation and the moisture management in
creating a cooling effect on the wearer's skin and ready
evaporation of perspiration, while still providing therapeutic
warmth without heat buildup.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a plan view of the inventive fabric.
DETAILED DESCRIPTION OF THE INVENTION
[0026] The fabric of the present invention may be produced on
either warp or weft (circular) basis. However, a warp, in
particular, a fine gauge tricot, is more facile in manufacture and
generally produces a better fabric. This is because a warp knit
system lends itself better to the formation of mesh structures than
does a circular knit system. In particular, warp knit meshes may be
produced without any special auxiliary elements, while circular
knit meshes require special knitting elements during production;
such elements are cumbersome to use and detract from knitting
efficiency.
[0027] There are a number of ways to generate an upstanding loop
pile for the inventive fabric. It may be accomplished by
overfeeding the warp threads so that the excess yarns are not
incorporated in the fabric structure collect on its surface in
order to form a loop pile effect. It may also be accomplished with
the aid of special loop forming elements such as using special
sinkers, points or blades, which manipulate the warp threads or
stitch components into a loop pile.
It may further be accomplished by employing the knitting technique
of releasing (pressing off) the surface loops using stitch
combination whereby certain stitches are drawn on one course and
then released or "pressed off" on the next course so as to create a
loop pile.
[0028] In the present invention, the fabric responds especially
well to a napping procedure, which is the preferred method for
generating a loop pile along one surface of the inventive fabric.
This results in the well known UBL (unbroken loop) velvet-like
fabric extensively used in apparel, footwear and Velcro (.RTM.)
closure systems. In particular, the yarn floats on the technical
reverse side of the inventive fabric are produced by thread members
connecting the wales. These yarn floats are disposed along the
surface of the fabric and become engaged during the process of
napping by the napper wires in order to produce a raised unbroken
loop pile. The length of the floats may be varied through
appropriate construction design of the inventive fabric.
[0029] Here, the yarn floats of the technical reverse side of the
tricot fabric are engaged by the napper wire and raised into an
unbroken loop pile in a closely controlled process. Napping
produces a soft, dense pile that is very compatible with the hook
members of the Velcro (.RTM.) closures and which is able to
withstand multiple open and close cycles.
[0030] Importantly, the napping procedure satisfies the stringent
requirements of the Velcro (.RTM.) closures. These stringent
requirements of the Velcro closure are: [0031] 1. the loop pile
should be of uniform height; [0032] 2. the loops should be firmly
anchored in the fabric base; and [0033] 3. the loops should be
strong enough to withstand the stresses and strains of repeatedly
opening and closing closure elements without failure and fraying of
the loop filaments.
[0034] The mesh construction of the inventive fabric is produced
during knitting. The mesh construction of the inventive fabric
increases the permeability of air so as to enhance the wearing
comfort by facilitating evaporation of perspiration and dissipating
skin heat buildup. A mesh construction is produced when there is no
connection between adjacent wales for one or more courses. When
this occurs, the tension inside the knit structure of the fabric
pulls the adjacent wales so as to form a mesh opening.
[0035] The mesh openings should have a mesh count of between about
5 and 8 meshes/inch in the width and between about 4 and 6
meshes/inch in the length.
[0036] In accordance with the invention, the filament yarns are
present in the inventive fabric in an amount of between about 85
and 95 weight percent and are blended with spandex present in the
inventive fabric in an amount between about 5 and 15 weight percent
of the fabric in order to impart the requisite amount of stretch.
In other words, the spandex yarns are knitted together with the
filament yarns to provide the inventive fabric with stretch in both
the width and the length. In the width, the fabric of the invention
has a stretch of between about 75% and 125%, while in the length
the stretch is between about 25% and 60%.
[0037] Almost any filament yarn of medium tenacity (between about 4
and 7 gram per denier) may be used here. The filament yarns should
have a denier of between about 40 and 70 and the number of
filaments per yarn is between about 10 and 24. However, nylon
filament is the preferred fiber because of its moisture,
absorption, pleasant touch against the skin, good response to the
napping process, ease of dyeing and resilience in Velcro (.RTM.)
action thanks to the elastic recovery of this fiber. Polyester yarn
is another option where lower cost and greater choice of yarn sizes
and filament counts are predominant considerations.
[0038] In the fabric embodiment described below, the yarns used are
40 denier 12 filament nylon and 40/1 denier clear spandex yarn
which imparts the fabric its stretch and recovery characteristics.
In general, the spandex yarn used in the inventive fabric will have
a denier between about 40 and 70.
[0039] Any one skilled in the art can specify a yarn system for a
specific consideration of fabric performance and economics. What is
meant by performance is the amount of pull or separating force the
Velcro (.RTM.) is designed to withstand, which depends on
application is sporting, orthopedic, industrial or other
devices.
[0040] Only one example of warp knit (tricot) fabric is provided.
Anyone skilled in the art can generate many constructional
permutations and combinations of yarn and stitch systems, which are
a matter of choice. The same applies to the choice of equipment,
its gauge (needles per inch), stitch configuration and processing
sequence.
EXAMPLE 1
[0041] One type of fabric of the invention is manufactured
utilizing a 4 guide bar, 28 gauge (28 needles/inch), tricot.
[0042] The yarns and their location relative to the guide bars used
in manufacture of the fabric of Example 1 are detailed below:
TABLE-US-00001 Bar 1 (Back) 40/1 clear Spandex 29 inch runner Bar 2
40/12 den Nylon 6, bright trilobal 50 inch runner Bar 3 40/12 den
Nylon 6, bright trilobal 50 inch runner Bar 4 (Front) 40/12 den
Nylon 6, bright trilobal 91 inch runner
[0043] Bars 2 and 3 create the mesh structure of the fabric, while
bar 4 produces long floats suitable for napping.
[0044] The threading chart for Example 1 is as follows:
TABLE-US-00002 Bar 1 (back) .......|||||||||| .|||||.|||||
|||||................... Bar 2 ....||||||||||||| .|||||||||||
||...................... Bar 3 .........|||||||| .|||||||||||
|||||||................ Bar 4 (front) .................
...||||||||| .......................
[0045] The stitch construction for Example 1 is as follows:
TABLE-US-00003 BAR 1 BAR 4 (Back) BAR 2 BAR 3 (Front) 1-0 7-8 1-0
1-0 1-2 7-6 1-2 3-4 7-8 1-0 1-0 7-6 1-2 3-4 6-5 2-3 1-0 5-4 3-4 3-4
4-3 4-5 6-7 3-2 5-6 9-10 2-1 6-7 7-6 1-0 7-8 9-10 1-2 7-6 7-6 1-0
7-8 9-10 1-2 7-6 7-6 2-3 6-5 9-10 3-4 5-4 7-6 4-5 4-3 4-3 5-6 3-2
1-0 6-7 2-1 3-4
[0046] The parameters for the fabric of Example 1 are as
follows:
TABLE-US-00004 Fabric width 60 inch Fabric weight 7.35 oz/yd. sq.
+5% Hand stretch 40% in length Shrinkage 5% in length and width
Courses 72 per inch Wales 52 per inch Elongation at break 40%
[0047] The fabric of Example 1 is jet dyed and napped on its
technical back.
[0048] The fabric of Example 1 may also be either napped or sueded
on its technical face in order to enhance its adhesion in bonding
to the foam material of the orthopedic device.
The scope of the invention will now be set forth in the following
claims.
* * * * *