U.S. patent application number 16/256438 was filed with the patent office on 2019-08-15 for cooling material.
This patent application is currently assigned to BEDGEAR, LLC. The applicant listed for this patent is BEDGEAR, LLC. Invention is credited to Eugene Alletto, JR..
Application Number | 20190249343 16/256438 |
Document ID | / |
Family ID | 65409512 |
Filed Date | 2019-08-15 |
United States Patent
Application |
20190249343 |
Kind Code |
A1 |
Alletto, JR.; Eugene |
August 15, 2019 |
COOLING MATERIAL
Abstract
A cooling material includes opposite top and bottom surfaces and
a central portion positioned between the top and bottom surfaces.
The top surface includes a first fiber. The bottom surface includes
a second fiber. The middle portion includes the first and second
fibers and a third fiber. Methods of manufacture are included.
Inventors: |
Alletto, JR.; Eugene; (Glen
Head, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
BEDGEAR, LLC |
Farmingdale |
NY |
US |
|
|
Assignee: |
BEDGEAR, LLC
Farmingdale
NY
|
Family ID: |
65409512 |
Appl. No.: |
16/256438 |
Filed: |
January 24, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62623306 |
Jan 29, 2018 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D04B 1/16 20130101; D02G
3/02 20130101; D10B 2331/021 20130101; D10B 2403/0114 20130101;
A47G 9/0215 20130101; A47G 9/1036 20130101; D02G 3/045 20130101;
D10B 2331/02 20130101; D10B 2503/06 20130101; D10B 2331/04
20130101; D10B 2505/08 20130101; D10B 2201/22 20130101; A47C 21/046
20130101 |
International
Class: |
D04B 1/16 20060101
D04B001/16 |
Claims
1. A cooling material comprising opposite top and bottom surfaces
and a central portion positioned between the top and bottom
surfaces, the top surface comprising a first fiber, the bottom
surface comprising a second fiber, the middle portion comprising
the first and second fibers and a third fiber.
2. A cooling material as recited in claim 1, wherein the first and
second fibers are nylon fibers and the third fiber is a rayon
fiber.
3. A cooling material as recited in claim 1, wherein the first and
second fibers comprise 52% rayon by weight and 48% nylon by
weight.
4. A cooling material as recited in claim 1, wherein the first and
second fibers are uncrimped nylon fibers and the third fiber is an
uncrimped rayon fiber.
5. A cooling material as recited in claim 1, wherein the first and
second fibers are nylon filaments and the third fiber is a rayon
filament.
6. A cooling material as recited in claim 1, wherein the first and
second fibers are nylon fibers and the third fiber is a polyester
fiber.
7. A cooling material as recited in claim 1, wherein the first and
second fibers are uncrimped nylon fibers and the third fiber is an
uncrimped polyester fiber.
8. A cooling material as recited in claim 1, wherein the first and
second fibers are nylon filaments and the third fiber is a
polyester filament.
9. A cooling material as recited in claim 1, wherein the first
fiber is spaced apart from the second fiber by the third fiber.
10. A cooling material as recited in claim 1, wherein the top
surface comprises spaced apart loops of the first fiber and the
bottom surface comprises spaced apart loops of the second
fiber.
11. A cooling material as recited in claim 1, wherein the middle
portion comprises spaced apart first loops of the second fiber and
spaced apart second loops of the second fiber, the first fiber
being positioned in the first loops and the second fiber being
positioned in the second loops.
12. A cooling material as recited in claim 1, wherein the middle
portion comprises spaced apart first loops of the second fiber and
spaced apart second loops of the second fiber, the first fiber
comprising loops that are positioned in the first loops and the
second fiber comprising loops that are positioned in the second
loops.
13. A cooling material as recited in claim 12, wherein the loops of
the first fiber are aligned with the first loops and the loops of
the second fiber are aligned with the second loops.
14. A cooling material as recited in claim 1, wherein the cooling
material has an average density between about 0.1% and about
2.0%.
15. A cooling material as recited in claim 1, wherein the cooling
material has an average density of 1.1%.
16. A cooling material as recited in claim 1, wherein the cooling
material has a boil-off shrinkage between about 5.0% and about
10.0%.
17. A cooling material as recited in claim 1, wherein the cooling
material has a boil-off shrinkage of 8.1%.
18. A blended yarn as recited in claim 1, wherein the cooling
material has a break elongation between about 10.0% and about
20.0%.
19. A cooling material as recited in claim 1, wherein the cooling
material has a break elongation of 14.4%.
20. A cooling material as recited in claim 1, wherein the cooling
material has a tenacity between about 3.0 CN/D and about 8.0
CN/D.
21. A cooling material as recited in claim 1, wherein the cooling
material has a tenacity of 5.51 CN/D.
22. A cooling material as recited in claim 1, wherein the cooling
material comprises between about 20 and about 60 wales per inch and
between about 35 and about 75 courses per inch.
23. A cooling material as recited in claim 1, wherein the cooling
material comprises 40 wales per inch and 55 courses per inch.
24. A cooling material comprising opposite top and bottom surfaces
and a central portion positioned between the top and bottom
surfaces, the top surface consisting of a first fiber, the bottom
surface consisting of a second fiber, the middle portion consisting
of the first and second fibers and a third fiber.
25. A cooling material as recited in claim 24, wherein the first
and second fibers are nylon fibers and the third fiber is a rayon
fiber.
26. A cooling material as recited in claim 24, wherein the first
and second fibers are nylon fibers and the third fiber is a rayon
fiber, the first and second fibers comprising 48% of the blended
yarn by weight and the third fiber comprising 52% of the blended
yarn by weight.
27. A cooling material as recited in claim 24, wherein the first
and second fibers are uncrimped nylon fibers and the third fiber is
an uncrimped rayon fiber.
28. A cooling material as recited in claim 24, wherein the first
and second fibers are nylon filaments and the third fiber is a
rayon filament.
29. A cooling material as recited in claim 24, wherein the first
and second fibers are nylon fibers and the third fiber is a
polyester fiber.
30. A cooling material as recited in claim 24, wherein the first
and second fibers are uncrimped nylon fibers and the third fiber is
an uncrimped polyester fiber.
31. A cooling material as recited in claim 24, wherein the first
and second fibers are nylon filaments and the third fiber is a
polyester filament.
32. A cooling material as recited in claim 24, wherein the first
fiber is spaced apart from the second fiber by the third fiber.
33. A cooling material comprising opposite top and bottom surfaces
and a central portion positioned between the top and bottom
surfaces, the top surface comprising a first fiber, the bottom
surface comprising a second fiber, the middle portion comprising
the first and second fibers and a third fiber, wherein at least one
of the first and second fibers comprises a nylon fiber and the
third fiber is a rayon fiber, the nylon fiber comprising flakes of
mica and flakes of nylon that are melted together and extruded to
form the nylon fiber.
Description
TECHNICAL FIELD
[0001] The present disclosure generally relates to cooling
materials, and more particularly to materials having cooling
effects. Methods of manufacture are included.
BACKGROUND
[0002] Sleep is critical for people to feel and perform their best,
in every aspect of their lives. Sleep is an essential path to
better health and reaching personal goals. Indeed, sleep affects
everything from the ability to commit new information to memory to
weight gain. It is therefore essential for people to use bedding
that suit both their personal sleep preference and body type in
order to achieve comfortable, restful sleep.
[0003] Selecting the appropriate type of bedding is an important
aspect in achieving proper sleep. For example, selecting a pillow,
mattress, mattress topper, etc. that is cool to the touch can
greatly affect how comfortable a user is when they sleep. Indeed,
materials that are cool to the touch may prevent the user from
overheating while he or she is sleeping and/or can create a
comfortable environment to allow the user to fall asleep more
quickly. However, conventional materials used to make bedding are
not cool to the touch, thus causing the sleeper discomfort, which
can prevent restful sleep. This disclosure describes an improvement
over these prior art technologies.
SUMMARY
[0004] In one embodiment, in accordance with the principles of the
present disclosure, a cooling material is provided that includes
opposite top and bottom surfaces and a central portion positioned
between the top and bottom surfaces. The top surface comprises a
first fiber. The bottom surface comprises a second fiber. The
middle portion comprises the first and second fibers and a third
fiber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The present disclosure will become more readily apparent
from the specific description accompanied by the following
drawings, in which:
[0006] FIG. 1 is a front view of one embodiment of a cooling
material in accordance with the present principles of the present
disclosure;
[0007] FIG. 2 is a back view of one embodiment of the cooling
material shown in FIG. 1;
[0008] FIG. 3 is a chart providing information on Yarn Content,
Yarn Specifications and Q-Max(W/cm.sup.2) of one embodiment of a
cooling material in accordance with the present principles of the
present disclosure; and
[0009] FIG. 4 is a chart providing information on Yarn Content,
Yarn Specifications and Melange Effect of one embodiment of a
cooling material in accordance with the present principles of the
present disclosure; and
[0010] FIG. 5 is a chart of example yarns shortlisted based on Qmax
and Melange Effect.
DETAILED DESCRIPTION
[0011] The exemplary embodiments of cooling materials and methods
of making cooling materials are discussed in terms of cooling
materials for use in bedding, such as, for example, pillows,
mattresses, mattress toppers, etc. The present disclosure may be
understood more readily by reference to the following detailed
description of the disclosure. It is to be understood that this
disclosure is not limited to the specific devices, methods,
conditions or parameters described and/or shown herein, and that
the terminology used herein is for the purpose of describing
particular embodiments by way of example only and is not intended
to be limiting of the claimed disclosure.
[0012] Also, as used in the specification and including the
appended claims, the singular forms "a," "an," and "the" include
the plural, and reference to a particular numerical value includes
at least that particular value, unless the context clearly dictates
otherwise. Ranges may be expressed herein as from "about" or
"approximately" one particular value and/or to "about" or
"approximately" another particular value. When such a range is
expressed, another embodiment includes from the one particular
value and/or to the other particular value. Similarly, when values
are expressed as approximations, by use of the antecedent "about,"
it will be understood that the particular value forms another
embodiment. It is also understood that all spatial references, such
as, for example, horizontal, vertical, top, upper, lower, bottom,
left and right, are for illustrative purposes only and can be
varied within the scope of the disclosure. For example, the
references "upper" and "lower" are relative and used only in the
context to the other and are not necessarily "superior" and
"inferior".
[0013] The following discussion includes a description of cooing
material 10. The components of material 10 can be fabricated from
materials including polymers and/or composites, depending on the
particular application. For example, material 10 can be fabricated
from materials such as fabrics or textiles, paper or cardboard,
cellulosic-based materials, biodegradable materials, plastics and
other polymers, semi-rigid and rigid materials. Material 10 may
also be fabricated from a heterogeneous material such as a
combination of two or more of the above-described materials.
Material 10 and/or components of material 10 can be extruded,
molded, injection molded, cast, pressed and/or machined.
[0014] Material 10 comprises a yarn that is extruded through
spinnerets by adding flakes or pellets of a cooling substance, such
as, for example, mica to flakes or pellets of raw material(s). Mica
is the name of potassium, magnesium, iron, aluminum, lithium and
other family layered silicate minerals. It is widely distributed on
the earth and is one of the familiar minerals in daily life. It has
stable chemical property and good thermal conductivity, water
absorption, adsorption property. Due to the thermal conductivity of
0.03, its transfer rate is 5 times higher than the polyester.
Mica's excellent thermal conductivity is mainly due to its layer
structure. It has been found that good heat conducting mica fiber
textiles can rapidly transferred body heat to the outside of
fabric, and it is very suitable for spring and summer cooling
product. Other cooling minerals e.g. cooling Jade can also be
added. The flakes or pellets of the cooling substance are melted
together with the flakes or pellets of the raw material(s) and as
the filaments come out of the spinneret, they are cooled. The
cooling process solidifies them and turns them into filaments. In
some embodiments, the raw material(s) is/are rayon, nylon and/or
polyester. In some embodiments, the raw material(s) is/are
uncrimped rayon filaments, uncrimped nylon filaments and/or
uncrimped polyester filaments. For example, in one embodiment,
material 10 includes a "cooling nylon" yarn wherein flakes or
pellets of mica are added to flakes or pellets of nylon. The mica
flakes or pellets are melted with the flakes or pellets of nylon to
form a composition that is extruded through a spinneret to form the
cooling nylon yarn as described above.
[0015] In one embodiment, material 10 comprises a "cooling rayon"
yarn wherein flakes or pellets of mica are added to flakes or
pellets of rayon. The mica flakes or pellets are melted with the
flakes or pellets of rayon to form a composition that is extruded
through a spinneret to form the cooling rayon yarn containing up to
about 60% by weight of mica flakes or pellets. In alternative
embodiments of the rayon composition of the present invention
comprises about 0.1% to about 50% by weight of mica flakes or
pellets, about 0.1% to about 45% by weight of mica flakes or
pellets, about 0.1% to about 40% by weight of mica flakes or
pellets, about 0.1% to about 35% by weight of mica flakes or
pellets, about 0.1% to about 30% by weight of mica flakes or
pellets, about 0.1% to about 25% by weight of mica flakes or
pellets, about 0.1% to about 20% by weight of mica flakes or
pellets, about 0.1% to about 15% by weight of mica flakes or
pellets; about 0.1% to about 10% by weight of mica flakes or
pellets; about 0.1% to about 5% by weight of mica flakes or
pellets, about 0.1% to about 2% by weight of mica flakes or pellets
or any combinations thereof.
[0016] In one embodiment, material 10 comprises a "cooling
polyester" yarn wherein flakes or pellets of mica are added to
flakes or pellets of polyester. The mica flakes or pellets are
melted with the flakes or pellets of polyester to form a
composition that is extruded through a spinneret to form the
cooling polyester yarn thread once cooled. The mica flakes or
pellets are melted with polyester to form a composition that is
extruded through a spinneret to form the cooling polyester yarn
containing up to about 60% by weight of mica flakes or pellets. In
alternative embodiments of the polyester composition of the present
invention comprises about 0.1% to about 50% by weight of mica
flakes or pellets, about 0.1% to about 45% by weight of mica flakes
or pellets, about 0.1% to about 40% by weight of mica flakes or
pellets, about 0.1% to about 35% by weight of mica flakes or
pellets, about 0.1% to about 30% by weight of mica flakes or
pellets, about 0.1% to about 25% by weight of mica flakes or
pellets, about 0.1% to about 20% by weight of mica flakes or
pellets, about 0.1% to about 15% by weight of mica flakes or
pellets; about 0.1% to about 10% by weight of mica flakes or
pellets; about 0.1% to about 5% by weight of mica flakes or
pellets, about 0.1% to about 2% by weight of mica flakes or pellets
or any combinations thereof.
[0017] In some embodiments, material 10 includes a yarn comprising
100% cooling nylon. In some embodiments, material 10 includes a
yarn comprising 100% cooling rayon. In some embodiments, material
10 includes a yarn comprising 100% cooling polyester.
[0018] It is envisioned that the yarns that make up material 10 may
be of different sizes and/or may comprise different numbers of
filaments. For example, material 10 may include a yarn comprising
denier from about 1D to about 200D and/or may include between about
10 and 200 filaments. In some embodiments, material 10 may include
a yarn comprising 75D/72F wicking polyester (75 Denier with 72
filaments) Wicking polyester is designed to pull sweat and moisture
away from skin toward the outside of fabric in order to evaporate
quicker. Synthetics like polyester are hydrophobic, meaning the
fabric doesn't like moisture or sweat. Wicking polyester has a
special cross-section and a large surface area, which picks up
moisture and carries it away from your body, spreading it out, to
evaporate easily on the outside of the fabric. They also have a
capillary action that moves moisture from areas of high
concentration to low concentration. Once the moisture reaches the
outside of the fabric, it evaporates, or moves on to the next layer
to start the process anew. So, you stay cool and dry. In some
embodiments, material 10 may include a yarn comprising 40D/34F
cooling nylon (40 Denier with 34 filaments). In some embodiments,
material 10 may include a yarn comprising 65% polyester and 35%
nylon wherein material 10 comprises 75D/72F wicking polyester (75
Denier with 72 filaments) and 40D/34F cooling nylon (40 Denier with
34 filaments). In some embodiments, material 10 may include a yarn
comprising 70D/68F cooling nylon (70 Denier with 68 filaments). In
some embodiments, material 10 may include a yarn comprising 52%
polyester and 48% nylon wherein material 10 comprises 75D/72F
wicking polyester (75 Denier with 72 filaments) and 70D/68F cooling
nylon (70 Denier with 68 filaments). In some embodiments, material
10 may include a yarn comprising two plies of 40D/34F cooling nylon
(40 Denier with 34 filaments).
[0019] A plied yarn is one where multiple strands of yarn--already
spun yarn--are put together and twisted in the opposite direction
from that in which they were first twisted. This gives the yarn
much more strength, durability and consistency than is seen in a
singles yarn. A 2-ply yarn has two strands; a 3-ply yarn has three
strands etc. You can have a very bulky two-ply yarn or an extremely
thin four-ply yarn depending on how the individual singles were
produced. In some embodiments, material 10 may include a yarn
comprising 48% polyester and 52% nylon wherein material 10
comprises 75D/72F wicking polyester (75 Denier with 72 filaments)
and two plies of 40D/34F cooling nylon (40 Denier with 34
filaments). In some embodiments, material 10 may include a yarn
comprising 75D/72F cooling polyester (75 Denier with 72 filaments).
In some embodiments, material 10 may include a yarn comprising 52%
polyester and 48% nylon wherein material 10 comprises 75D/72F
cooling polyester (75 Denier with 72 filaments) and 70D/68F cooling
nylon (70 Denier with 68 filaments).
[0020] In some embodiments, material 10 may include a yarn
comprising 145D/140F cooling polyester. In some embodiments,
material 10 may include a yarn comprising 52% polyester and 48%
nylon wherein material 10 comprises 145D/140F cooling polyester
(145 Denier with 140 filaments) and nylon blended. Nylon blended
means a nylon yarn which is twisted together with other fibers e.g.
polyester to make a blended yarn having beneficial properties. In
some embodiments, material 10 may include a yarn comprising 26%
polyester and 74% nylon wherein material 10 comprises 145D/140F
cooling polyester (145 Denier with 140 filaments), nylon and
140D/136F cooling nylon (140 Denier with 136 filaments). This is
done just to achieve different levels of cooling. If we don't want
fabric to be 100% cooling then we can blend it with non-cooling
yarns. In some embodiments, material 10 may include a yarn
comprising 24% polyester and 76% nylon wherein material 10
comprises 145D/140F cooling polyester (145 Denier with 140
filaments), nylon and 150D/144F cooling nylon (150 Denier with 144
filaments). In some embodiments, material 10 may include a yarn
comprising 52% rayon and 48% nylon wherein material 10 comprises
75D/72F cooling rayon (75 Denier with 72 filaments) and 70D/68F
cooling nylon (70 Denier with 68 filaments). In some embodiments,
material 10 may include a yarn comprising 52% rayon and 48% nylon
wherein material 10 comprises 145D/140F cooling rayon (145 Denier
with 140 filaments) and nylon blended.
[0021] In some embodiments, material 10 may include a yarn
comprising 26% rayon and 74% nylon wherein material 10 comprises
145D/140F cooling rayon (145 Denier with 140 filaments), nylon
blended and 140D/136F cooling nylon (140 Denier with 136
filaments). In some embodiments, material 10 may include a yarn
comprising 24% rayon and 76% nylon wherein material 10 comprises
145D/140F cooling rayon (145 Denier with 140 filaments), nylon
blended and 150D/144F cooling nylon (150 Denier with 144
filaments). In some embodiments, material 10 may include a yarn
comprising 50% rayon and 50% polyester wherein material 10
comprises 75D/72F cooling rayon (75 Denier with 72 filaments) and
75D/72F cooling polyester (75 Denier with 72 filaments). In some
embodiments, material 10 may include a yarn comprising 50% rayon
and 50% polyester wherein material 10 comprises 150D/144F cooling
rayon (150 Denier with 144 filaments) and polyester blended.
[0022] In some embodiments, material 10 may include a yarn
comprising 50% rayon and 50% polyester wherein material 10
comprises 150D/144F cooling rayon (150 Denier with 144 filaments)
and polyester blended. In some embodiments, material 10 may include
a yarn comprising 25% rayon and 75% polyester wherein material 10
comprises 150D/144F cooling rayon (150 Denier with 144 filaments),
polyester blended and 150D/144F cooling polyester (150 Denier with
144 filaments). In some embodiments, material 10 may include a type
of polyester blended yarn where cooling polyester filaments are
twisted together with regular filaments to form a poly blended
yarn. This is done just to achieve different levels of cooling. In
some embodiments, material 10 may include a type of polyester
blended yarn without non-cooling yarns. In some embodiments,
material 10 may include a yarn comprising 75% rayon and 25%
polyester wherein material 10 comprises 150D/144F cooling rayon
(150 Denier with 144 filaments), polyester blended and 150D/144F
cooling polyester (150 Denier with 144 filaments). In some
embodiments, material 10 may include a yarn comprising 100%
140D/136F cooling nylon (140 Denier with 136 filaments). In some
embodiments, material 10 may include a yarn comprising 100%
150D/144F cooling rayon (150 Denier with 144 filaments). In some
embodiments, material 10 may include a yarn comprising 100%
150D/144F cooling polyester (150 Denier with 144 filaments).
[0023] It is envisioned that the yarns that make up material 10 may
have different densities. For example, material 10 may have an
average density between about 0.1% and about 5.0%. In some
embodiments, material 10 has an average density between about 0.5%
and about 1.6%. In some embodiments, material 10 has an average
density of 1.1%.
[0024] It is envisioned that the yarns that make up material 10 may
have different boil-off shrinkages. For example, material 10 may
have a boil-off shrinkage between about 1.0% and about 15.0%. In
some embodiments, material 10 has a boil-off shrinkage between
about 4.0% and about 12.0%. In some embodiments, material 10 has a
boil-off shrinkage of 8.1%.
[0025] It is envisioned that the yarns that make up material 10 may
have different break elongations. For example, material 10 may have
a break elongation between about 5.0% and about 20.0%. In some
embodiments, material 10 has a break elongation between about 12.0%
and about 16.0%. In some embodiments, material 10 has a break
elongation of 14.4%.
[0026] It is envisioned that the yarns that make up material 10 may
have different tenacities. For example, material 10 may have a
tenacity between about 0.1 CN/D and about 10.0 CN/D. In some
embodiments, material 10 has a tenacity between about 3.0 CN/D and
about 7.0 CN/D. In some embodiments, material 10 has a tenacity of
5.51 CN/D.
[0027] In some embodiments, the yarns that make up material 10 may
are knitted to form material 10. For example, material 10 may be
formed using a weft knitting method, such as, for example, a
circular knitting technique. The yarns are run in wales and courses
wherein the wales are perpendicular to the course of the yarn. In
some embodiments, material 10 has about 20 to about 60 wales per
inch and about 35 to about 75 courses per inch. In some
embodiments, material 10 has about 30 to about 50 wales per inch
and about 45 to about 65 courses per inch. In some embodiments,
material 10 has 40 wales per inch and 55 courses per inch.
[0028] Material 10 comprises a top surface 12 and an opposite
bottom surface 14. A central portion 16 is positioned between
surfaces 12, 14. Surface 12 comprises a fiber 18, surface comprises
a fiber 20, and portion 16 comprises fibers 18, 20 and a fiber 22.
At least one of fibers 18, 20 includes a material, such as, for
example, one or more of the cooling materials discussed herein. In
some embodiments, at least one of fibers 18, 20 includes nylon,
rayon and/or polyester. In some embodiments, at least one of fibers
18, 20 includes cooling nylon, cooling rayon and/or cooling
polyester. Fiber 22 is configured to maintain fibers 18, 20 such
that a user's skin will only contact fiber 18 and/or fiber 20 when
the user touches material 10. That is, the user's skin will not
directly contact fiber 22 when the user touches material 10.
[0029] In some embodiments, fiber 18 and/or fiber 20 may comprise a
material, such as, for example, rayon, nylon and/or polyester that
is cool to the touch such that when the user touches material 10
fiber 18 and/or fiber 20 will provide a cooling effect. In some
embodiments, fiber 18 and/or fiber 20 may comprise a material, such
as, for example, cooling rayon, cooling nylon and/or cooling
polyester that is cool to the touch such that when the user touches
material 10 fiber 18 and/or fiber 20 will provide a cooling effect.
In some embodiments, fiber 22 is the same as at least one of fibers
18, 20. For example, fiber 22 may be made from the same or similar
materials as at least one of fibers 18, 20. In some embodiments,
fiber 22 is different than at least one of fibers 18, 20. For
example, fiber 22 may be made from different materials than at
least one of fibers 18, 20. As discussed herein, forming at least
one of fibers 18, 20 from a cooling material, such as, for example,
one or more of the cooling materials discussed herein, provides a
cooling effect when touched. As such, while at least one of fibers
18, 20 is made from a material that provides a cooling effect,
fiber 22 is not required to be made from a material that provides a
cooling effect. Therefore, in some embodiments, fiber 22 is made
from a material that provides a cooling effect and in other
embodiments, fiber 22 is not made from a material that provides a
cooling effect.
[0030] As shown in FIGS. 1 and 2, material 10 is made by forming
fiber 20 to have a plurality of loops, such as, for example, loops
20a, 20b, 20c and forming fiber 22 to have a plurality of loops,
such as, for example, loops 22a, 22b, 22c. Fiber 20 includes a loop
20d that is positioned between loops 20a, 20b and a loop 20e that
is positioned between loops 20b, 20c. Loops 20d, 20e are positioned
opposite of loops 20a, 20b, 20c. Fiber 22 includes a loop 22d that
is positioned between loops 22a, 22b and a loop 22e that is
positioned between loops 22b, 22c. Loops 22d, 22e are positioned
opposite of loops 22a, 22b, 22c. Loop 22a is positioned through
loop 20a using a circular knitting technique such that loop 22a is
aligned with loop 20a. Loop 22b is positioned through loop 20b
using a circular knitting technique such that loop 22b is aligned
with loop 20b. Loop 22c is positioned through loop 20c using a
circular knitting technique such that loop 22c is aligned with loop
20c. Loop 20d is positioned through loop 22d using a circular
knitting technique such that loop 22d is aligned with loop 20d.
Loop 20e is positioned through loop 22e using a circular knitting
technique such that loop 22e is aligned with loop 20e.
[0031] Fiber 18 is formed to have a plurality of loops, such as,
for example, loops 18a, 18b, 18c. Fiber 18 includes a loop 18d that
is positioned between loops 18a, 18b and a loop 18e that is
positioned between loops 18b, 18c. Loops 18d, 18e are positioned
opposite of loops 18a, 18b, 18c. Loop 18a is positioned through
loop 22a using a circular knitting technique such that loop 18a is
aligned with loop 20a and loop 22a. Loop 18b is positioned through
loop 22b using a circular knitting technique such that loop 18b is
aligned with loop 20b and loop 22b. Loop 18c is positioned through
loop 22c using a circular knitting technique such that loop 18c is
aligned with loop 20c and loop 22c. Loop 22d is positioned through
loop 18d using a circular knitting technique such that loop 22d is
aligned with loop 18d and loop 20d. Loop 22e is positioned through
loop 18e using a circular knitting technique such that loop 22e is
aligned with loop 18e and loop 20e. This configuration allows loops
18a, 18b, 18c to form top surface 12 of material 10 and loops 20d,
20e to form bottom surface 14 of material 10, as shown in FIGS. 1
and 2.
[0032] At least one of fibers 18, 20 includes a material, such as,
for example, one or more of the cooling materials discussed herein.
In some embodiments, at least one of fibers 18, 20 includes nylon,
rayon and/or polyester. In some embodiments, at least one of fibers
18, 20 includes cooling nylon, cooling rayon and/or cooling
polyester. In some embodiments, at least one of fibers 18, 20
includes nylon, rayon, polyester, cooling nylon, cooling rayon
and/or cooling polyester. In some embodiments, at least one of
fibers 18, 20 includes cooling nylon and/or cooling rayon. In some
embodiments, at least one of fibers 18, 20 includes cooling
polyester and/or cooling rayon. In some embodiments, at least one
of fibers 18, 20 includes cooling nylon and/or cooling polyester.
In some embodiments, fiber 18 includes cooling nylon and fiber 20
includes cooling rayon. In some embodiments, fiber 18 includes
cooling rayon and fiber 20 includes cooling nylon. In some
embodiments, fiber 18 includes cooling polyester and fiber 20
includes cooling rayon. In some embodiments, fiber 18 includes
cooling rayon and fiber 20 includes cooling polyester. In some
embodiments, fiber 18 includes cooling nylon and fiber 20 includes
cooling polyester. In some embodiments, fiber 18 includes cooling
polyester and fiber 20 includes cooling nylon.
[0033] In some embodiments, fiber 18 and/or fiber 20 include(s) a
blend of materials such that fiber 18 and/or fiber is/are a blended
yarn. For example, in some embodiments, fiber 18 and/or fiber 20
may comprise 65% polyester and 35% nylon wherein fiber 18 and/or
fiber 20 comprises 75D/72F wicking polyester (75 Denier with 72
filaments) and 40D/34F cooling nylon (40 Denier with 34 filaments).
In some embodiments, fiber 18 and/or fiber 20 may comprise 52%
polyester and 48% nylon wherein fiber 18 and/or fiber 20 comprises
75D/72F wicking polyester (75 Denier with 72 filaments) and 70D/68F
cooling nylon (70 Denier with 68 filaments). In some embodiments,
fiber 18 and/or fiber 20 may include two plies of 40D/34F cooling
nylon (40 Denier with 34 filaments). In some embodiments, fiber 18
and/or fiber 20 comprises 48% polyester and 52% nylon wherein fiber
18 and/or fiber 20 comprises 75D/72F wicking polyester (75 Denier
with 72 filaments) and two plies of 40D/34F cooling nylon (40
Denier with 34 filaments). In some embodiments, fiber 18 and/or
fiber 20 comprises 75D/72F cooling polyester (75 Denier with 72
filaments). In some embodiments, fiber 18 and/or fiber 20 comprises
52% polyester and 48% nylon wherein fiber 18 and/or fiber 20
comprises 75D/72F cooling polyester (75 Denier with 72 filaments)
and 70D/68F cooling nylon (70 Denier with 68 filaments).
[0034] In some embodiments, fiber 18 and/or fiber 20 comprises
145D/140F cooling polyester (145 Denier with 140 filaments). In
some embodiments, fiber 18 and/or fiber 20 comprises 52% polyester
and 48% nylon wherein fiber 18 and/or fiber 20 comprises 145D/140F
cooling polyester (145 Denier with 140 filaments) and nylon
blended. In some embodiments, fiber 18 and/or fiber 20 comprises
26% polyester and 74% nylon wherein fiber 18 and/or fiber 20
comprises 145D/140F cooling polyester (145 Denier with 140
filaments), nylon and 140D/136F cooling nylon (140 Denier with 136
filaments). In some embodiments, fiber 18 and/or fiber 20 comprises
24% polyester and 76% nylon wherein fiber 18 and/or fiber 20
comprises 145D/140F cooling polyester (145 Denier with 140
filaments), nylon and 150D/144F cooling nylon (150 Denier with 144
filaments). In some embodiments, fiber 18 and/or fiber 20 comprises
52% rayon and 48% nylon wherein fiber 18 and/or fiber 20 comprises
75D/72F cooling rayon (75 Denier with 72 filaments) and 70D/68F
cooling nylon (70 Denier with 68 filaments). In some embodiments,
fiber 18 and/or fiber 20 comprises 52% rayon and 48% nylon wherein
fiber 18 and/or fiber 20 comprises 145D/140F cooling rayon (145
Denier with 140 filaments) and nylon blended.
[0035] In some embodiments, fiber 18 and/or fiber 20 comprises 26%
rayon and 74% nylon wherein fiber 18 and/or fiber 20 comprises
145D/140F cooling rayon (145 Denier with 140 filaments), nylon
blended and 140D/136F cooling nylon (140 Denier with 136
filaments). In some embodiments, fiber 18 and/or fiber 20 comprises
24% rayon and 76% nylon wherein fiber 18 and/or fiber 20 comprises
145D/140F cooling rayon (145 Denier with 140 filaments), nylon
blended and 150D/144F cooling nylon (150 Denier with 144
filaments). In some embodiments, fiber 18 and/or fiber 20 comprises
50% rayon and 50% polyester wherein fiber 18 and/or fiber 20
comprises 75D/72F cooling rayon (75 Denier with 72 filaments) and
75D/72F cooling polyester (75 Denier with 72 filaments). In some
embodiments, fiber 18 and/or fiber 20 comprises 50% rayon and 50%
polyester wherein fiber 18 and/or fiber 20 comprises 150D/144F
cooling rayon (150 Denier with 144 filaments) and polyester
blended.
[0036] In some embodiments, fiber 18 and/or fiber 20 comprises 50%
rayon and 50% polyester wherein fiber 18 and/or fiber 20 comprises
150D/144F cooling rayon (150 Denier with 144 filaments) and
polyester blended. In some embodiments, fiber 18 and/or fiber 20
comprises 25% rayon and 75% polyester wherein fiber 18 and/or fiber
20 comprises 150D/144F cooling rayon (150 Denier with 144
filaments), polyester blended and 150D/144F cooling polyester (150
Denier with 144 filaments). In some embodiments, fiber 18 and/or
fiber 20 comprises 75% rayon and 25% polyester wherein fiber 18
and/or fiber 20 comprises 150D/144F cooling rayon (150 Denier with
144 filaments), polyester blended and 150D/144F cooling polyester
(150 Denier with 144 filaments). In some embodiments, fiber 18
and/or fiber 20 comprises 100% 140D/136F cooling nylon (140 Denier
with 136 filaments). In some embodiments, fiber 18 and/or fiber 20
comprises 100% 150D/144F cooling rayon (150 Denier with 144
filaments). In some embodiments, fiber 18 and/or fiber 20 comprises
100% 150D/144F cooling polyester (150 Denier with 144
filaments).
Example 1
[0037] The maximum level of the contact heat flow q-max
(W/cm.sup.2) of various yarns was determined to assess the
suitability of such yarns for use in cooling materials, such as,
for example, cooling material 10. The q-max for each yarn was
determined by measuring the peak value of heat current immediately
after the heat stored on a pure copper plate (area: 9 cm.sup.2,
weight: 9.79 g) travels to a specimen when the plate touches the
surface of the specimen. The q-max for each yarn tested is shown in
FIG. 3. As shown in FIG. 5, a range of yarns were looked at in
order to decide which yarn will be most suitable for as a suitable
cooling fabric. Yarns were shortlisted based of their Qmax
properties and melange effect.
[0038] While it was expected that yarns that include blends of only
cooling nylon, cooling rayon and/or cooling polyester would have
higher q-max scores than yarns that include blends of cooling
nylon, cooling rayon and/or cooling polyester and nylon, rayon
and/or polyester, as shown in FIG. 3, the yarn that included
cooling rayon and nylon had a higher q-max score than the yarn that
included cooling rayon and cooling nylon (0.359/0.301 and
0.33/0.29).
Example 2
[0039] The melange effect of various yarns was determined to assess
the suitability of such yarns for use in cooling materials, such
as, for example, cooling material 10. In some examples, the melange
effect is a color effect achieved by cross dyeing fabric made from
more than one type of fiber. The process involving dipping the
fabric into several different dye baths specifically chosen for
their affinity to the fibers so that each fiber type will only
absorb certain dyes. In order to create melange yarn, the fiber is
usually dyed before spinning. The melange effect for each yarn
tested is shown in FIG. 4. As shown in FIG. 4, yarns that include
blends of only cooling nylon, cooling rayon and/or cooling
polyester have an uneven melange effect and yarns that include
blends of cooling nylon, cooling rayon and/or cooling polyester and
nylon, rayon and/or polyester have an even melange effect. In that
yarns that include blends of cooling nylon, cooling rayon and/or
cooling polyester and nylon, rayon and/or polyester have an even
melange effect and have q-max scores that are higher than yarns
that include blends of only cooling nylon, cooling rayon and/or
cooling polyester (and have an uneven melange effect), it may be
preferable to use yarns that include blends of cooling nylon,
cooling rayon and/or cooling polyester and nylon, rayon and/or
polyester over yarns that include blends of only cooling nylon,
cooling rayon and/or cooling polyester for use in a cooling
material, such as, for example, cooling material 10, since such
yarns have been shown to demonstrate superior q-max scores and
melange effects.
[0040] It will be understood that various modifications may be made
to the embodiments disclosed herein. For example, features of any
one embodiment can be combined with features of any other
embodiment. Therefore, the above description should not be
construed as limiting, but merely as exemplification of the various
embodiments. Those skilled in the art will envision other
modifications within the scope and spirit of the claims appended
hereto.
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