U.S. patent application number 12/551736 was filed with the patent office on 2010-03-04 for lightweight, cut and/or abrasion resistant garments, and related protective wear.
This patent application is currently assigned to Nathaniel H. Kolmes. Invention is credited to Dan Brittain, James Edward Herring, Nathaniel H. KOLMES.
Application Number | 20100050699 12/551736 |
Document ID | / |
Family ID | 43649613 |
Filed Date | 2010-03-04 |
United States Patent
Application |
20100050699 |
Kind Code |
A1 |
KOLMES; Nathaniel H. ; et
al. |
March 4, 2010 |
LIGHTWEIGHT, CUT AND/OR ABRASION RESISTANT GARMENTS, AND RELATED
PROTECTIVE WEAR
Abstract
The present invention relates to a cut and/or abrasion resistant
garment that is lightweight, has improved comfort, flexibility and
pliability and provides a cooling effect on the wearer, and is
particularly suitable for use as hosiery products such as
stockings, pantyhose and tights, or for protective coverings for
the arms of the wearer.
Inventors: |
KOLMES; Nathaniel H.;
(Hickory, NC) ; Brittain; Dan; (Hickory, NC)
; Herring; James Edward; (ChattanoogA, TN) |
Correspondence
Address: |
OBLON, SPIVAK, MCCLELLAND MAIER & NEUSTADT, L.L.P.
1940 DUKE STREET
ALEXANDRIA
VA
22314
US
|
Assignee: |
Nathaniel H. Kolmes
Hickory
NC
|
Family ID: |
43649613 |
Appl. No.: |
12/551736 |
Filed: |
September 1, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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12134446 |
Jun 6, 2008 |
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12551736 |
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Current U.S.
Class: |
66/174 ; 66/175;
66/176; 66/178R; 66/202 |
Current CPC
Class: |
A41B 9/00 20130101; D10B
2321/0211 20130101; A41B 11/00 20130101; D04B 1/16 20130101; A41B
17/00 20130101; D10B 2501/02 20130101; D04B 1/246 20130101; D04B
1/28 20130101; D04B 1/243 20130101; D04B 1/26 20130101; D10B
2403/0114 20130101; D10B 2401/063 20130101; D10B 2501/04
20130101 |
Class at
Publication: |
66/174 ; 66/175;
66/176; 66/178.R; 66/202 |
International
Class: |
D04B 39/00 20060101
D04B039/00; A41D 19/00 20060101 A41D019/00; A41B 9/08 20060101
A41B009/08; A41B 1/00 20060101 A41B001/00; A41B 9/00 20060101
A41B009/00 |
Claims
1. A cut and/or abrasion resistant knit fabric, comprising: at
least one high tenacity nylon yarn and at least one high
performance yarn, wherein each yarn in the fabric has a denier of
from 10 to 325, wherein the fabric has a fabric weight of 7 OPSY or
less and a cut resistance according to ASTM-1790 of 1.5 or
higher.
2. The cut and/or abrasion resistant knit fabric of claim 1,
wherein the fabric comprises yarns having a sum of all deniers of
from 100 to 800.
3. The cut and/or abrasion resistant knit fabric of claim 1,
wherein the at least one high tenacity nylon yarn and at least one
high performance yarn combined comprise at least 50% by weight of
all yarns making up the fabric.
4. The cut and/or abrasion resistant knit fabric of claim 1,
wherein the fabric is knit from at least 4 ends, wherein the at
least 4 ends comprise the at least one high tenacity nylon yarn and
at least one high performance yarn.
5. The cut and/or abrasion resistant knit fabric of claim 1,
wherein one or both of the at least one high tenacity nylon yarn
and at least one high performance yarn are a composite yarn.
6. The cut and/or abrasion resistant knit fabric of claim 1,
further comprising at least one wicking yarn.
7. The cut and/or abrasion resistant knit fabric of claim 1,
wherein at least one yarn is antimicrobial.
8. The cut and/or abrasion resistant knit fabric of claim 4,
wherein the at least 4 ends comprise at least 2 ends of high
tenacity nylon yarn and at least 2 ends of high performance
yarn.
9. The cut and/or abrasion resistant knit fabric of claim 1,
wherein the high tenacity nylon yarn is a composite yarn comprising
a high tenacity nylon yarn.
10. The cut and/or abrasion resistant knit fabric of claim 9,
wherein the composite yarn comprises at least one high tenacity
nylon yarn as core and a first cover layer of a member selected
from the group consisting of high performance yarns, thermoplastic
yarns and wicking yarns, wherein any one or more components of the
composite yarn can optionally be antimicrobial.
11. The cut and/or abrasion resistant knit fabric of claim 9,
wherein the composite yarn comprises at least one high tenacity
nylon yarn as core, a first cover layer of at least one high
performance yarn, and a second cover layer of one member selected
from the group consisting of high performance yarns, thermoplastic
yarns, and wicking yarns, wherein any one or more components of the
composite yarn can optionally be antimicrobial.
12. A cut and/or abrasion resistant knit garment formed from the
fabric of claim 1.
13. The cut and/or abrasion resistant knit garment of claim 12,
wherein the garment is a member selected from the group consisting
of socks, stockings, full or partial arm coverings, gloves,
undershirts, underpants, bodysuits, and pantyhose.
14. The cut and/or abrasion resistant knit garment of claim 13,
wherein the garment is stockings.
15. The cut and/or abrasion resistant knit garment of claim 14,
wherein the stockings comprise a foot portion and a leg portion,
wherein the leg portion comprises the at least one high tenacity
nylon yarn and at least one high performance yarn.
16. The cut and/or abrasion resistant knit garment of claim 15,
wherein both the foot portion and the leg portion comprises the at
least one high tenacity nylon yarn and at least one high
performance yarn.
17. The cut and/or abrasion resistant knit garment of claim 13,
wherein the garment is a full or partial arm covering.
18. The cut and/or abrasion resistant knit garment of claim 17,
wherein the full or partial arm covering further comprises a glove
portion.
19. The cut and/or abrasion resistant knit garment of claim 13,
wherein the garment is an undershirt.
20. The cut and/or abrasion resistant knit garment of claim 19,
wherein the undershirt is short sleeved.
21. The cut and/or abrasion resistant knit garment of claim 19,
wherein the undershirt is long sleeved.
22. The cut and/or abrasion resistant knit garment of claim 19,
wherein the undershirt is a tank-top.
23. The cut and/or abrasion resistant knit garment of claim 13,
wherein the garment is a bodysuit.
24. The cut and/or abrasion resistant knit garment of claim 13,
wherein the garment is underpants.
Description
REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation-in-Part of U.S.
application Ser. No. 12/134,446, filed Jun. 6, 2008, the entire
contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] The present invention relates generally to protective
garments that are lightweight, having improved comfort, flexibility
and pliability, and are cut and/or abrasion resistant, particularly
suitable for use as hosiery products such as pantyhose and tights,
or for protective coverings for the limbs of the wearer.
[0004] 2. Discussion of the Background
[0005] In many activities, it is desirable to provide protective
garments, including undergarments, to protect participants from
being cut. Ideally, such garments should be flexible, pliable, soft
and cut/abrasion resistant. For activities in the sporting arena,
the garments also need to be light weight, and preferably
breathable and/or wicking to allow the removal and evaporation of
perspiration from the athlete. Typically, any improvement in the
cut and/or abrasion resistance has usually been at the sacrifice of
the other properties. Protective garments have been made cut
resistant in the past through the use of yarns which contain wire,
fiberglass and high denier high performance yarns such as aramids.
However, the use of wire is problematic in environments where a
protective garment must not be electrically or thermally
conductive. Moreover, experience has shown that the wire may break
and injure the hand of the wearer. Lastly, articles or garments
having a high wire content may be difficult and/or expensive to
clean using conventional cleaning techniques. Further, the use of
fiberglass can create significant problems with comfort,
particularly in a light weight construction undergarment, as the
glass fibers tend to cause significant skin irritation. Anyone that
has worked with installing fiberglass batting as insulation can
attest to this. The use of high denier high performance yarns such
as aramids is problematic in causing the yarn and resultant garment
to be too bulky for use, particularly in sporting applications.
[0006] In response to these problems, non-metallic cut-resistant
yarns have been developed. These yarns have been described in U.S.
Pat. Nos. 5,177,948 and 5,845,476 to Kolmes et al. which are owned
by the assignee of the present invention. The contents of these
patents are incorporated herein by reference. Kolmes '948 describes
a yarn having substantially parallel core strands which may include
fiberglass. Kolmes '476 describes other non-metal containing yarn
constructions which contain fiberglass as a core yarn. However,
these yarns are typically too bulky in denier to be used in
undergarments, hosiery or other intimate apparel.
[0007] Another problem that often arises when providing cut and/or
abrasion resistant fabric is that the fabric must often be too
heavy for comfort in order to provide the cut and abrasion
resistance. The resulting fabrics also tend to be uncomfortable due
to buildup of heat for the wearer.
[0008] There remains a need for a cut and/or abrasion-resistant
garment that is lightweight and suitable for use as hosiery, or
other undergarment types having improved flexibility and softness,
and avoids heat buildup.
SUMMARY OF THE INVENTION
[0009] Accordingly, one object of the present invention is to
provide a cut and/or abrasion resistant garment that is
lightweight, has improved comfort, flexibility and pliability.
[0010] A further object of the present invention is to provide a
cut and/or abrasion resistant garment that avoids heat buildup.
[0011] A further object of the present invention is to provide a
cut an/or abrasion resistant garment that actually reduces the
wearer's temperature during use (i.e. provides a cooling
effect).
[0012] A further object of the present invention is to provide a
garment suitable for use as hosiery products (such as stockings,
pantyhose, leggings, or tights, etc), for use as a full or partial
arm covering, optionally including a glove portion, undershirts,
underpants, bodysuits, or gloves, which is also cut and/or abrasion
resistant.
[0013] These and other objects of the present invention, alone or
in combinations thereof, have been satisfied by the discovery of a
cut and/or abrasion resistant knit fabric, comprising at least one
high tenacity nylon and at least one high performance yarn, wherein
each yarn has a denier of from 10 to 325, having a fabric weight of
7 OPSY or less and a cut resistance according to ASTM-1790 of 1.5
or higher.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The various benefits and advantages of the present invention
will be more apparent upon reading the following detailed
description of the invention taken in conjunction with the
drawings.
[0015] In the drawings, wherein like reference numbers identify a
corresponding component:
[0016] FIG. 1 illustrates an exemplary embodiment of the garment of
the present invention, namely pantyhose (10) having a foot portion
(15), a leg portion (16) and a panty portion (17).
[0017] FIG. 2 illustrates an exemplary embodiment of the garment of
the present invention, namely stockings (20) having a foot portion
(25) and a leg portion (26).
[0018] FIG. 3 illustrates an exemplary embodiment of a composite
yarn (30) having a core (31), a first cover layer (32) and a second
cover layer (33).
[0019] FIGS. 4A-4C illustrate exemplary embodiments of undershirts
of the present invention, including short-sleeved (4A),
long-sleeved (4B), and tank-top (4C).
DETAILED DESCRIPTION OF THE INVENTION
[0020] The term "fiber" as used herein refers to a fundamental
component used in the assembly of yarns and fabrics. Generally, a
fiber is a component which has a length dimension which is much
greater than its diameter or width. This term includes ribbon,
strip, staple, and other forms of chopped, cut or discontinuous
fiber and the like having a regular or irregular cross section.
"Fiber" also includes a plurality of any one of the above or a
combination of the above.
[0021] As used herein, the term "high performance fiber" means that
class of synthetic or natural non-glass fibers having high values
of tenacity greater than 10 g/denier, such that they lend
themselves for applications where high abrasion and/or cut
resistance is important. Typically, high performance fibers have a
very high degree of molecular orientation and crystallinity in the
final fiber structure.
[0022] The term "filament" as used herein refers to a fiber of
indefinite or extreme length such as found naturally in silk. This
term also refers to manufactured fibers produced by, among other
things, extrusion processes. Individual filaments making up a fiber
may have any one of a variety of cross sections to include round,
serrated or crenular, bean-shaped or others.
[0023] The term "intimate blend" as used herein refers to a mixture
of fibers of at least two types, wherein the mixture is formed in
such a way that the individual filaments of each type of fiber are
substantially completely intermixed with individual filaments of
the other types to provide a substantially homogeneous mixture of
fibers, having sufficient entanglement to maintain its integrity in
further processing and use.
[0024] The term "stretch broken" as used herein refers to a process
in which fibers are hot stretched and broken to produce short fiber
lengths, rather than cutting, in order to prevent some of the
damage done by the cutting process.
[0025] The term "yarn" as used herein refers to a continuous strand
of textile fibers, filaments or material in a form suitable for
knitting, weaving, or otherwise intertwining to form a textile
fabric. Yarn can occur in a variety of forms to include a spun yarn
consisting of staple fibers usually bound together by twist; a
multi filament yarn consisting of many continuous filaments or
strands; or a mono filament yarn which consists of a single strand.
A "blended yarn" as used herein refers to a yarn that comprises an
intimate blend of at least two different types of fibers.
[0026] The term "end" as used herein refers to a single yarn ply
used in preparation of multi-end yarns. The two or more ends may be
put together by twisting together, wrapping a cover wrap around the
combined ends or by air-interlacing as described below.
[0027] The term "composite yarn" refers to a yarn prepared from two
or more yarns, which can be the same or different. Composite yarn
can occur in a variety of forms wherein the two or more yarns are
in differing orientations relative to one another. The two or more
yarns can, for example, be parallel, wrapped one around the
other(s), twisted together, or combinations of any or all of these,
as well as other orientations, depending on the properties of the
composite yarn desired. Examples of such composite yarns are
provided in U.S. Pat. No. 4,777,789, U.S. Pat. No. 4,838,017, U.S.
Pat. No. 4,936,085, U.S. Pat. No. 5,177,948, U.S. Pat. No.
5,628,172, U.S. Pat. No. 5,632,137, U.S. Pat. No. 5,644,907, U.S.
Pat. No. 5,655,358, U.S. Pat. No. 5,845,476, U.S. Pat. No.
6,212,914, U.S. Pat. No. 6,230,524, U.S. Pat. No. 6,341,483, U.S.
Pat. No. 6,349,531, U.S. Pat. No. 6,363,703, U.S. Pat. No.
6,367,290, and U.S. Pat. No. 6,381,940, the contents of each of
which are hereby incorporated by reference.
[0028] The term "air interlacing" as used herein refers to
subjecting multiple strands of yarn to an air jet to combine the
strands and thus form a single, intermittently commingled strand.
This treatment is sometimes referred to as "air tacking." This term
is not used to refer to the process of "intermingling" or
"entangling" which is understood in the art to refer to a method of
air compacting a multifilament yarn to facilitate its further
processing, particularly in weaving processes. A yarn strand that
has been intermingled typically is not combined with another yarn.
Rather, the individual multifilament strands are entangled with
each other within the confines of the single strand. This air
compacting is used as a substitute for yarn sizing and as a means
to provide improved pick resistance. This term also does not refer
to well known air texturizing performed to increase the bulk of
single yarn or multiple yarn strands. Methods of air interlacing in
composite yarns and suitable apparatus therefore are described in
U.S. Pat. Nos. 6,349,531; 6,341,483; and 6,212,914, the relevant
portions of which are hereby incorporated by reference.
[0029] The term "composite fabric" is used herein to indicate a
fabric prepared from two or more different types of yarn or
composite yarn. The fabric construction can be any type, including
but not limited to, woven, knitted, non-woven, etc. The two or more
different types of yarn or composite yarn include, but are not
limited to, those made from natural fibers, synthetic fibers and
combinations thereof.
[0030] The term "composite article" is used herein to indicate a
final article that comprises at least two different types of
materials. The composite article can be prepared from a composite
fabric, or can be prepared from a conventional fabric containing
only one type of yarn, but is put together using a yarn or sewing
thread made of a different material. Alternatively, the
conventional fabric can be sewn together using a composite yarn as
the sewing thread. Composite articles can be any form, including
but not limited to, gloves, aprons, socks, filters, shirts, pants,
undergarments, one-piece jumpsuits, etc. All of these types of
articles, as well as other permutations that are readily evident to
those of skill in the art, are included in the present invention
definition of "composite article".
[0031] For convenience, the term "yarn component" as used herein,
encompasses fiber, monofilament, multifilament and yarn.
[0032] The present invention relates to lightweight fabrics that
are cut and/or abrasion resistant, have stretch properties, and are
particularly suitable for use in preparing garments such as hosiery
or tights. The fabrics have lower denier, softer feel, and more
comfort for wearers of the garments made from them, compared to
fabrics made from conventional cut and/or abrasion resistant yarns.
The garments include, but are not limited to, hosiery (including
pantyhose), tights, leggings, full or partial arm coverings (which
may include glove portions), gloves, undershirts (which may, for
example, be short-sleeved, long-sleeved or tank top style),
underpants (which may, for example, be shorts or full length),
bodysuits, etc. The fabrics can be made by knitting individual
yarns of multiple types to create a composite article containing no
composite yarns, as well as by knitting yarns of multiple types,
wherein one or more of the yarns being knitted is a composite
yarn.
[0033] One challenge has been to provide a fabric that is
lightweight enough to be made into articles such as undergarments,
gloves, hosiery, socks, etc. but which can also provide cut and/or
abrasion resistance to the wearer. The garment of the present
invention comprises a fabric selected from two basic types: 1) a
fabric made by knitting together at least one high performance yarn
and at least one high tenacity nylon yarn, and 2) a fabric made by
knitting at least one high performance yarn and at least one high
tenacity nylon yarn, with one or both of these being substituted by
a composite yarn comprising one or both of these types of yarn.
[0034] The yarn used in the present invention can optionally
contain an elastomeric yarn if desired. As the elastomeric yarn
component, any elastomeric fiber may be used, as monofilament or
multifilament yarn. Additionally, two or more elastomeric fibers
can be combined in the core of a composite yarn, or used as a
blend, twisted, in parallel, or air-tacked, etc. An elastomer is a
natural or synthetic polymer that, at room temperature, can be
stretched and expanded to typically twice its original length.
After removal of the tensile load it will immediately return to its
original length. Along with spandex, rubber and anidex (no longer
produced in the United States) are considered elastomeric fibers.
Spun from a block copolymer, spandex fibers exploit the high
crystallinity and hardness of polyurethane segments, yet remain
"rubbery" due to alternating segments of polyethylene glycol.
Suitable elastomeric fibers include, but are not limited to, fibers
made from copolymers having both rigid and flexible segments in the
polymer chains, such as, for example, block copolymers of
polyurethane and polyethylene glycol. Particularly suitable
elastomeric fibers include, but are not limited to, Spandex, such
as LYCRA (produced by United Yarn Products), ELASPAN (produced by
Invista), DORLASTAN (produced by Bayer), CLEAR SPAN (produced by
Radici) and LINEL (produced by Fillattice).
[0035] Elastomeric yarns can have one or more of the following
materials properties: can be stretched over 500% without breaking;
able to be stretched repetitively and still recover original
length; lightweight; abrasion resistant; poor strength, but
stronger and more durable than rubber; soft, smooth, and supple;
resistant to body oils, perspiration, lotions, and detergents; no
static or pilling problem; very comfortable; and easily dyed.
[0036] The elastomeric yarn can be any desired denier, preferably
from 10 to 210, more preferably from 15 to 150, most preferably
from 20 to 75. The elastomeric yarn can be used alone or combined
with one or more other yarns of any desired type, so long as the
combination retains its elastomeric properties. If combined with
one or more other yarns, the elastomeric yarn and other yarns are
preferably blended, or the one or more other yarns are wrapped
around the elastomeric yarn to provide an elastomeric core
composite yarn, thus retaining the stretch property.
[0037] Elastomeric yarn containing composite yarns are further
described in U.S. Pat. Nos. 5,568,657 and 5,442,815, the contents
of which are incorporated herein by reference. Elastomeric yarn
containing composite yarns having wicking properties are described
in U.S. Provisional Application Ser. No. 61/020,790, filed Jan. 14,
2008, the contents of which are hereby incorporated by
reference.
[0038] The high performance fiber of the present invention can be
any desired high performance fiber. Preferably the high performance
fiber comprises a high molecular weight polyolefin, preferably
ultra-high molecular weight polyethylene (UHMWPE) or high molecular
weight polypropylene, an aramid, a high molecular weight polyvinyl
alcohol, a high molecular weight polyacrylonitrile, liquid crystal
polyesters or mixtures or copolymers thereof. The high performance
fiber can also be a fiber blend, such as those described in U.S.
Pat. No. 7,214,425, hereby incorporated by reference, wherein the
high performance fiber is preferably included as a stretch broken
fiber blended with one or more other yarns, which may also be high
performance fibers themselves if desired.
[0039] U.S. Pat. No. 4,457,985, hereby incorporated by reference,
generally discusses high molecular weight polyethylene and
polypropylene fibers. In the case of polyethylene, suitable fibers
are those of molecular weight of at least 150,000, preferably at
least 400,000, more preferably at least one million and most
preferably between two million and five million. Such extended
chain polyethylene (ECPE) (or ultra-high molecular weight
polyethylene, UHMWPE) fibers may be grown in solution as described
in U.S. Pat. No. 4,137,394 or U.S. Pat. No. 4,356,138, hereby
incorporated by reference, or may be a filament spun from a
solution to form a gel structure, as described in German Off. 3 004
699 and GB 2 051 667, and especially described in U.S. Pat. No.
4,551,296, hereby incorporated by reference. As used herein, the
term polyethylene preferably means a predominantly linear
polyethylene material that may contain minor amounts of chain
branching or comonomers not exceeding 5 modifying units per 100
main chain carbon atoms, and that may also contain admixed
therewith not more than about 50 weight percent of one or more
polymeric additives such as alkene-1-polymers, in particular low
density polyethylene, polypropylene or polybutylene, copolymers
containing mono-olefins as primary monomers, oxidized polyolefins,
graft polyolefin copolymers and polyoxymethylenes, or low molecular
weight additives such as lubricants, colorants and the like which
are commonly incorporated by reference. Depending upon the
formation technique, the draw ratio and temperatures, and other
conditions, a variety of properties can be imparted to these
fibers. The tenacity of the fibers should preferably be at least 15
g/d, more preferably at least 20 g/d, even more preferably at least
25 g/d and most preferably at least 28 g/d. Similarly, the tensile
modulus of the filaments, as measured by an Instron tensile testing
machine, is preferably at least 300 g/d, more preferably at least
500 g/d and still more preferably at least 1,000 g/d and most
preferably at least 1,200 g/d. These highest values for tensile
modulus and tenacity are generally obtainable only by employing
solution grown or gel fiber processes. For example, ultra-high
molecular weight polyethylene filaments produced commercially by
Honeywell Corp. under the trade name SPECTRA or by DSM under the
trade name DYNEEMA and having moderately high moduli and tenacity
are particularly useful.
[0040] Similarly, highly oriented polypropylene of molecular weight
at least 200,000, preferably at least one million and more
preferably at least two million, may be used. Such high molecular
weight polypropylene may be formed into reasonably well oriented
fibers by techniques described in the various references referred
to above, and especially by the technique of U.S. Pat. Nos.
4,663,101 and 4,784,820, hereby incorporated by reference, and U.S.
patent application Ser. No. 069,684, filed Jul. 6, 1987 (see
published application WO 89 00213). Since polypropylene is a much
less crystalline material than polyethylene and contains pendant
methyl groups, tenacity values achievable with polypropylene are
generally substantially lower than the corresponding values for
polyethylene. Accordingly, a suitable tenacity is at least about 8
g/d, with a preferred tenacity being at least about 11 g/d. The
tensile modulus for polypropylene is at least about 160 g/d,
preferably at least about 200 g/d.
[0041] In the case of aramid fibers, suitable aramid filaments
formed principally from aromatic polyamide are described in U.S.
Pat. No. 3,671,542, which is hereby incorporated by reference.
Preferred aramid fiber will have a tenacity of at least about 20
g/d, a tensile modulus of at least about 400 g/d and an
energy-to-break at least about 8 joules/g, and particularly
preferred aramid fiber will have a tenacity of at least about 20
g/d, a modulus of at least about 480 g/d and an energy-to-break of
at least about 20 joules/g. Most preferred aramid fiber will have a
tenacity of at least about 20 g/d, a modulus of at least about 900
g/d and an energy-to-break of at least about 30 joules/g. For
example, poly(p-phenylene terephthalamide) filaments produced
commercially by Dupont Corporation under the trade name of KEVLAR
and having moderately high moduli and tenacity values are
particularly useful.
[0042] High molecular weight polyvinyl alcohol fibers having high
tensile modulus are described in U.S. Pat. No. 4,440,711, hereby
incorporated by reference. Particularly useful PV-OH fiber should
have a modulus of at least about 300 g/d, a tenacity of at least
about 7 g/d (preferably at least about 10 g/d, more preferably
about 14 g/d, and most preferably at least about 17 g/d), and an
energy-to-break of at least about 8 joules/g. PV-OH fiber having a
weight average molecular weight of at least about 200,000, a
tenacity of at least about 10 g/d, a modulus of at least about 300
g/d, and an energy to break of about 8 joules/g is more useful.
PV-OH fiber having such properties can be produced, for example, by
the process disclosed in U.S. Pat. No. 4,599,267.
[0043] In the case of polyacrylonitrile (PAN), PAN fibers for use
in the present invention are of molecular weight of at least about
400,000. Particularly useful PAN fibers should have a tenacity of
at least about 10 g/d and an energy-to-break of at least about 8
joules/g. PAN fibers having a molecular weight of at least about
400,000, a tenacity of at least about 15 to about 20 g/d and an
energy-to-break of at least about 8 joule/g are most useful. Such
fibers are disclosed, for example, in U.S. Pat. No. 4,535,027.
[0044] Useful liquid crystalline polymers include lyrotropic liquid
crystalline polymers which include polypeptides such as poly
.gamma.-benzyl L-glutamate and the like; aromatic polyamides such
as poly(1,4-benzamide), poly(chloro-1-4-phenylene terephthalamide),
poly(1,4-phenylene fumaramide), poly(chloro-1,4-phenylene
fumaramide), poly(4,4'-benzanilide trans, trans-muconamide),
poly(1,4-phenylene mesaconamide), poly(1,4-phenylene)
(trans-1,4-cyclohexylene amide), poly(chloro-1,4-phenylene)
(trans-1,4-cyclohexylene amide), poly(1,4-phenylene
1,4-dimethyl-trans-1,4-cyclohexylene amide), poly(1,4-phenylene
2,5-pyridine amide), poly(chloro-1,4-phenylene 2,5-pyridine amide),
poly(3,3'-dimethyl-4,4'-biphenylene 2,5 pyridine amide),
poly(1,4-phenylene 4,4'-stilbene amide), poly(chloro-1,4-phenylene
4,4'-stilbene amide), poly(1,4-phenylene 4,4'-azobenzene amide),
poly(4,4'-azobenzene 4,4'-azobenzene amide), poly(1,4-phenylene
4,4'-azoxybenzene amide), poly(4,4'-azobenzene 4,4'-azoxybenzene
amide), poly(1,4-cyclohexylene 4,4'-azobenzene amide),
poly(4,4'-azobenzene terephthal amide), poly(3,8-phenanthridinone
terephthal amide), poly(4,4'-biphenylene terephthal amide),
poly(4,4'-biphenylene 4,4'-bibenzo amide), poly(1,4-phenylene
4,4'-bibenzo amide), poly(1,4-phenylene 4,4'-terephenylene amide),
poly(1,4-phenylene 2,6-naphthal amide), poly(1,5-naphthalene
terephthal amide), poly(3,3'-dimethyl-4,4-biphenylene terephthal
amide), poly(3,3'-dimethoxy-4,4'-biphenylene terephthal amide),
poly(3,3'-dimethoxy-4,4-biphenylene 4,4'-bibenzo amide) and the
like; polyoxamides such as those derived from
2,2'-dimethyl-4,4'-diamino biphenyl and chloro-1,4-phenylene
diamine; polyhydrazides such as poly chloroterephthalic hydrazide,
2,5-pyridine dicarboxylic acid hydrazide) poly(terephthalic
hydrazide), poly(terephthalic-chloroterephthalic hydrazide) and the
like; poly(amidehydrazides) such as poly(terephthaloyl 1,4
aminobenzhydrazide) and those prepared from 4-aminobenzhydrazide,
oxalic dihydrazide, terephthalic dihydrazide and para-aromatic
diacid chlorides; polyesters such as those of the compositions
include
poly(oxy-trans-1,4-cyclohexyleneoxycarbonyl-trans-1,4-cyclohexylenecarbon-
yl-b-oxy-1,4-phenyl-eneoxyteraphthaloyl) and
poly(oxy-cis-1,4-cyclohexyleneoxycarbonyl-trans-1,4-cyclohexylenecarbonyl-
-b-oxy-1,4-phenyleneoxyterephthaloyl) in methylene
chloride-o-cresol poly(oxy-trans-1,4-cyclohexylene
oxycarbonyl-trans-1,4-cyclohexylenecarbonyl-b-oxy-(2-methyl-1,4-phenylene-
) oxy-terephthaloyl) in
1,1,2,2-tetrachloroethane-o-chlorophenolphenol (60:25:15
vol/vol/vol),
poly[oxy-trans-1,4-cyclohexyleneoxycarbonyl-trans-1,4-cyclohexylenecarbon-
yl-b-oxy(2-methyl-1,3-phenylene)oxy-terephthaloyl] in
o-chlorophenol and the like; polyazomethines such as those prepared
from 4,4'-diaminobenzanilide and terephthalaldehyde,
methyl-1,4-phenylenediamine and terephthalaldehyde and the like;
polyisocyanides such as poly(-phenyl ethyl isocyanide),
poly(n-octyl isocyanide) and the like; polyisocyanates such as
poly(n-alkyl isocyanates) as for example poly(n-butyl isocyanate),
poly(n-hexyl isocyanate) and the like; lyrotropic crystalline
polymers with heterocyclic units such as
poly(1,4-phenylene-2,6-benzobisthiazole) (PBT),
poly(1,4-phenylene-2,6-benzobisoxazole) (PBO),
poly(1,4-phenylene-1,3,4-oxadiazole),
poly(1,4-phenylene-2,6-benzobisimidazole),
poly[2,5(6)-benzimidazole] (AB-PBI),
poly[2,6-(1,4-phenylene-4-phenylquinoline]
poly[1,1'-(4,4'-biphenylene)-6,6'-bis(4-phenylquinoline)] and the
like; polyorganophosphazines such as polyphosphazine,
polybisphenoxyphosphazine, poly[bis(2,2,2' trifluoroethylene)
phosphazine] and the like; metal polymers such as those derived by
condensation of trans-bis(tri-n-butylphosphine)platinum dichloride
with a bisacetylene or
trans-bis(tri-n-butylphosphine)bis(1,4-butadinynyl)platinum and
similar combinations in the presence of cuprous iodine and an
amide; cellulose and cellulose derivatives such as esters of
cellulose as for example triacetate cellulose, acetate cellulose,
acetate-butyrate cellulose, nitrate cellulose, and sulfate
cellulose, ethers of cellulose as for example, ethyl ether
cellulose, hydroxymethyl ether cellulose, hydroxypropyl ether
cellulose, carboxymethyl ether cellulose, ethyl hydroxyethyl ether
cellulose, cyanoethylethyl ether cellulose, ether-esters of
cellulose as for example acetoxyethyl ether cellulose and
benzoyloxypropyl ether cellulose, and urethane cellulose as for
example phenyl urethane cellulose; thermotropic liquid crystalline
polymers such as celluloses and their derivatives as for example
hydroxypropyl cellulose, ethyl cellulose propionoxypropyl
cellulose; thermotropic copolyesters as for example copolymers of
6-hydroxy-2-naphthoic acid and p-hydroxy benzoic acid, copolymers
of 6-hydroxy-2-naphthoic acid, terephthalic acid and hydroquinone
and copolymers of poly(ethylene terephthalate) and p-hydroxybenzoic
acid; and thermotropic polyamides and thermotropic
copoly(amide-esters).
[0045] The high performance yarn can be any desired denier,
preferably from 10 to 325, more preferably from 50 to 250, most
preferably from 100 to 220.
[0046] The high tenacity nylon used in the present invention can be
made from any desired polyamide, including, but not limited to,
nylon-6,6, nylon-6, nylon-12, etc. The high tenacity nylon has a
tenacity of at least 8 g/den, more preferably at least 10 g/den,
more preferably at least 15 g/den. The high tenacity nylon has a
denier of from 10 to 150, preferably from 25 to 100, more
preferably from 50 to 90.
[0047] In the fabric of the present invention, the combination of
high performance yarn and high tenacity nylon preferably comprises
50% or more, by weight, of the yarns making up the fabric. More
preferably, the combination of high performance yarn and high
tenacity nylon comprises 50-70% by weight of the yarns making up
the fabric.
[0048] In a preferred embodiment, the composition uses an ultra
high molecular weight polyethylene that is air tacked or covered
with the high tenacity nylon yarn. In a most preferred embodiment,
the ultra high molecular weight polyethylene is a 150 denier yarn,
and is air tacked or covered with a 70 denier high tenacity
nylon.
[0049] The fabric of the present invention has been found to have
not only excellent cut and abrasion resistance properties, but
surprisingly, also provides a cooling effect on the wearer.
[0050] If wicking properties are desired in the garment, one or
more wicking yarns can be incorporated into the fabric making up
the garment. The one or more wicking yarns can be used as one or
more of the ends being knitted, can be air-tacked with one of the
other yarns being knitted (such as the at least one elastomeric
yarn or at least one high performance yarn), or can be part of a
composite yarn that is used as one or more ends in the knitting
process. Any wicking yarns can be used. Wicking yarns act by
pulling moisture away from the wearer's skin, and permitting
evaporation from the surface of the yarn, thus keeping the wearer
drier. The wicking properties are conventionally provided by
extruding the yarn (typically a hydrophilic yarn such as polyester,
nylon or acrylic) such that it has one or more grooves or
capillaries running lengthwise, which can move moisture away from
the wearer through capillary action. Such capillary based fibers
include, but are not limited to, COOLMAX fibers (by Invista), 4DG
fibers and Q-WICK fibers (by Fiber Innovation Technology, Inc), and
COOLNEW fibers (by Cyarn).
[0051] Additionally, wicking yarns can be prepared by use of a
hydrophobic fiber, such as polyolefin fiber. Such fibers include,
but are not limited to, DRYMAX fibers (by Drymax, LLC) and HYDROFIL
fibers (Allied Signal). The wicking yarn can be any desired denier,
and is preferably from 40 to 300 denier, more preferably from 50 to
200 denier, most preferably from 50 to 150 denier, and can be used
as a single end or multiple ends.
[0052] If one or more ends being knitted is a composite yarn, each
of the cover layers included within the composite yarn will have a
wrapping rate, measured as turns per inch (tpi), which can be any
desired amount sufficient to provide the integrity and workability
of the yarn. Preferably the wrapping rate is from 4 to 19 tpi, more
preferably from 6 to 12. Of course, the tpi will further depend on
the denier of the yarn used for the cover layer and on the
composite denier of the structure around which the cover layer is
being wrapped. This variation in tpi can be readily determined by
one of ordinary skill in the art.
[0053] If desired, the present invention fabric, or the yarns used
to make the fabric, can be rendered antimicrobial, using the
process described in U.S. Patent Publication 2005/0186259, the
contents of which are hereby incorporated by reference. This can
provide the wearer of articles made from the present invention
fabric with added protection from infections microorganisms, as the
antimicrobial treatment provides a "contact" kill of the
microbe.
[0054] Additionally, it is possible to dye the entire fabric in a
single dye step, using the above noted antimicrobial treatment as a
"dye auxiliary", as described in U.S. Patent Publication
2006/0088712, the contents of which are hereby incorporated by
reference. This allows a one step dyeing to achieve uniform color
of all components of the composite yarn. If antimicrobial
properties are then desired, the antimicrobial treatment can then
be applied again after dyeing.
[0055] In knitting the fabric of the present invention, one can use
any conventional knitting machine. The knitting machine can have
any desired number of feeds, depending on the number needed to
cover the number of yarn types being knitted and the speed at which
the knitting will occur. Typically knitting machines have 2, 4 or 8
feeds, with the most common being 4 or 8 feeds. In a most preferred
embodiment of the present invention, the garment is made using a 4
feed hosiery knitting machine. In knitting the garments of the
present invention, each feed can use yarn having deniers ranging
from 10 to 325 denier, preferably from 20-250 denier. The total
denier of the yarns making up the garment can be any desired,
depending on the weight of garment to be produced. In particular,
the total denier of yarns used is preferably from 100 to 800
denier, most preferably from 100 to 400.
[0056] The resulting fabric preferably has a weight of 7 ounces per
square yard (OPSY) or less, more preferably 5 OPSY or less, most
preferably 4.5 OPSY or less. The OPSY measurement typically has a
.+-.5% accuracy. This provides an extremely lightweight fabric,
having still significantly high cut resistance of level 1.5 or
higher (in accordance with ASTM-1790), more preferably level 2 or
higher.
[0057] In the knitting process, the differing yarns can be knit
together as different ends, one or more types can be laid-in in the
knitting process, ends can be plaited together, etc. Stitch types
can be any desired, including but not limited to knit-tuck, jersey,
interlock, mesh, and any stitch possible on 4 inch or larger
circular knit equipment.
[0058] In an exemplary embodiment, a 4 feed knitting machine is
used to knit at least one feed of high performance yarn and at
least one feed of high tenacity nylon yarn. If the high performance
yarn and high tenacity nylon yarn are the only yarns to be used in
the construction of the garment, the 4 total feeds can be divided
between the yarn types in any manner to obtain the desired
properties in the knitted product. For example, the feeds can be
evenly split with 2 feeds of high performance yarn and 2 feeds of
high tenacity nylon yarn to provide a hosiery product having a good
balance of high cut and/or abrasion resistance and stretch
properties, while maintaining light weight. If more stretch
property is needed and less cut and/or abrasion resistance is
acceptable, the feeds can be divided as 1 feed of high performance
yarn and 3 feeds of high tenacity nylon yarn. Alternatively, if
less stretch is needed and more cut and/or abrasion resistance is
desired, the feeds can be divided as 3 feeds of high performance
yarn and 1 feed of high tenacity nylon yarn.
[0059] As noted above, either or both of the high performance yarn
and high tenacity nylon yarn can be replaced with a composite yarn
comprising either or both of a high performance yarn or high
tenacity nylon yarn. All feeds of the knitting process can use a
composite yarn. As noted above, composite yarns can be made wicking
and/or antimicrobial as desired. Additionally, one or more of the
feeds of high performance yarn or high tenacity nylon yarn can be
substituted by a wicking yarn or antimicrobial yarn. Alternatively,
a wicking yarn or other type of yarn can be air-tacked to either of
the high performance yarn or high tenacity nylon yarn as
desired.
[0060] In a most preferred embodiment of the present invention, the
garment is hosiery or tights. Hosiery is typically constructed as
stockings or pantyhose. In stockings (30) (see FIG. 2), the
knitting process can differentiate between the leg portion (35) and
the foot portion (36). In pantyhose (10) (see FIG. 1), the leg (16)
and foot (15) portion can be differentiated, and there is a third
portion, the panty portion (17). In the present invention, the most
important portion of hosiery for cut and/or abrasion resistance is
the leg portion, particularly if the hosiery is to be used by
competitive skaters, hockey players, or other professional
athletes, where the foot has added protection from the skate or
shoe. However, if desired, the entire stocking or pantyhose, or any
combination of the foot, leg and/or panty, can be made as cut
and/or abrasion resistant using the present invention, if
desired.
[0061] In another embodiment of the present invention, the fabric
is formed into a garment that is an undershirt. Exemplary
embodiments of undershirt are illustrated by FIGS. 4A-4C, which
show a short-sleeved undershirt (4A), a long-sleeved undershirt
(4B), and a tank-top style undershirt (4C). In the undershirts, any
part of the shirt can be prepared from the present invention
fabric, or the entire undershirt can be prepared from the present
invention fabric to provide the highest level of protection to the
wearer.
[0062] Of course, in leggings, the entire leg covering would be
according to the present invention most preferably. In tights, the
leg portion or the panty portion or both could be made cut and/or
abrasion resistant using the present invention. In the construction
of arm coverings, the entire arm portion would preferably be made
cut and/or abrasion resistant using the present invention.
[0063] This provides the present fabrics with the property of being
light weight, having low denier of the component yarns, and being
useful particularly in preparation of hosiery or tights, leggings,
arm coverings, etc. In addition, it is possible to make the present
fabric in the form of an undershirt, underpants, socks, etc., if
desired.
[0064] The fabric of the present invention provides cut and/or
abrasion resistance while maintaining a high level of comfort.
Garments made from such fabrics are particularly useful to
competitive ice skaters, hockey players, football players,
bicyclists, motorcyclists, and a variety of other wearers engaged
in activities likely to result in cuts or abrasion being inflicted
on the body. The present invention has solved that problem by
providing a fabric that is lightweight, breathable, can be made
wicking and/or antimicrobial, provides a high level of cut and/or
abrasion resistance, and provides a cooling effect to the
wearer.
[0065] Although the present invention has been described with
preferred embodiments, it is to be understood that modifications
and variations may be utilized without departing from the spirit
and scope of this invention, as those skilled in the art would
readily understand. Such modifications and variations are
considered to be within the purview and scope of the appended
claims and their equivalents.
EXAMPLES
[0066] Suitable examples of high performance fibers used in the
present invention include: [0067] 220 denier ultra-high molecular
weight polyethylene (UHMWPE) air tacked to 100 denier high tenacity
nylon [0068] 150 denier ultra-high molecular weight polyethylene
(UHMWPE) wrapped with 70 denier high tenacity nylon [0069] 150
denier ultra-high molecular weight polyethylene (UHMWPE) air tacked
to 70 denier high tenacity nylon Suitable fabrics in the present
invention include, but are not limited to: [0070] 1) A mini mesh
fabric having a fabric weight of 3.21 OPSY, formed from the
following yarns: [0071] 52% of 150 denier ultrahigh molecular
weight polyethylene (UHMWPE) air tacked with 70 denier high
tenacity nylon [0072] 38% of 70 denier polyester [0073] 10% of 40
denier nylon [0074] 2) A two-layered modified interlock fabric
having a fabric weight of 4.25 OPSY formed from the following
yarns: [0075] 65% of 150 denier ultrahigh molecular weight
polyethylene (UHMWPE) air tacked with 70 denier high tenacity nylon
[0076] 21% of 70 denier polyester [0077] 14% of 40 denier nylon
[0078] 3) A mini mesh fabric having a fabric weight of 3.21 OPSY,
formed from the following yarns: [0079] 52% of 150 denier ultrahigh
molecular weight polyethylene (UHMWPE) covered with 70 denier high
tenacity nylon [0080] 38% of 70 denier polyester [0081] 10% of 40
denier nylon [0082] 4) A two-layered modified interlock fabric
having a fabric weight of 4.25 OPSY formed from the following
yarns: [0083] 65% of 150 denier ultrahigh molecular weight
polyethylene (UHMWPE) covered with 70 denier high tenacity nylon
[0084] 21% of 70 denier polyester [0085] 14% of 40 denier nylon
[0086] Fabric 2 above was formed into a bicycling shirt having
fabric weight of 4.25 OPSY (.+-.5%). This was compared to a
commercially available shirt sold under the tradename UnDShurt, a
bicycling shirt made of microdenier acrylic fibers (90%) and
polyester (10%) sold by DeFeet, reportedly having a fabric weight
of approximately 3 OPSY. The temperature of the surface of the
wearer was measured after 8 minutes of pedaling using infrared
photography both with and without a fan while wearing each shirt.
The results of the test are shown in the table below.
TABLE-US-00001 Temp after 5 mins pedaling Temp after 5 mins
pedaling without fan with fan blowing at 8 mph Shirt made from
present 79.8.degree. F. 70.9.degree. F. invention fabric UnDShurt
(from DeFeet) 82.6.degree. F. 79.7.degree. F.
As shown in the above data, the present invention fabric not only
provide a lower temperature (cooler feeling) for the wearer after 5
mins pedaling without the fan, but also provided a much lower
temperature after 5 mins pedaling with a fan blowing on the wearer
at 8 mph. Additionally, the temperature drop provided by the
present invention going from no fan to with a fan was nearly 3
times that of the comparative product. The present invention fabric
provided more cooling effect, despite having a higher fabric weight
than the comparative product!
* * * * *