U.S. patent application number 16/861794 was filed with the patent office on 2020-08-13 for insulating double-knit fabric.
The applicant listed for this patent is MMI-IPCO, LLC. Invention is credited to Marina Kozera, William Patz, William Michael Rose, Gary S. Smith, Gadalia Vainer.
Application Number | 20200255987 16/861794 |
Document ID | / |
Family ID | 65630758 |
Filed Date | 2020-08-13 |
View All Diagrams
United States Patent
Application |
20200255987 |
Kind Code |
A1 |
Rose; William Michael ; et
al. |
August 13, 2020 |
INSULATING DOUBLE-KNIT FABRIC
Abstract
The invention related to an insulating, double-knit fabric
comprising an outer knit layer and an inner knit layer coupled with
the outer knit layer forming a plurality of elongated air pockets
in a plurality of rows. Only the outer layer comprises a plurality
of windows, where the air pockets comprise intermediate fiber
regions and the intermediate fiber regions comprise fibers
positioned parallel to the inner and outer knit layers.
Inventors: |
Rose; William Michael; (East
Hampstead, NH) ; Smith; Gary S.; (Lee, NH) ;
Kozera; Marina; (Charlotte, NC) ; Patz; William;
(Belmont, NC) ; Vainer; Gadalia; (Melrose,
MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MMI-IPCO, LLC |
Spartanburg |
SC |
US |
|
|
Family ID: |
65630758 |
Appl. No.: |
16/861794 |
Filed: |
April 29, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16130657 |
Sep 13, 2018 |
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16861794 |
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62557950 |
Sep 13, 2017 |
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62692012 |
Jun 29, 2018 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D10B 2403/033 20130101;
D03D 11/02 20130101; D04B 1/24 20130101; D04B 21/16 20130101; D10B
2403/0243 20130101; A41D 31/065 20190201; D04B 1/16 20130101; D10B
2403/0222 20130101; D10B 2401/04 20130101; A41D 2500/10 20130101;
A41D 2400/10 20130101; D10B 2401/10 20130101; D10B 2403/0223
20130101; A41D 31/06 20190201; D03D 25/005 20130101 |
International
Class: |
D03D 11/02 20060101
D03D011/02; A41D 31/06 20060101 A41D031/06; D04B 1/24 20060101
D04B001/24; D03D 25/00 20060101 D03D025/00 |
Claims
1. An insulating, double-knit fabric comprising an outer knit layer
and an inner knit layer coupled with the outer knit layer forming a
plurality of elongated air pockets in a plurality of rows, wherein
only the outer layer comprises a plurality of windows, wherein the
air pockets comprise intermediate fiber regions, and wherein the
intermediate fiber regions comprise fibers positioned parallel to
the inner and outer knit layers.
2. The insulating, double-knit fabric of claim 1, wherein the
windows are spaced apart in the outer knit layer.
3. The insulating, double-knit fabric of claim 1, wherein the
fibers in the intermediate fiber regions have a length greater than
at least five times the width of the windows in the outer knit
layer.
4. The insulating, double-knit fabric of claim 1, wherein the first
knit layer comprises first yarns and the second knit layer
comprises second yarns, wherein the first knit layer and the second
knit layer comprise a denier gradient such that the first yarns
have a finer denier than the second yarns or the second yarns have
a finer denier than the first yarns.
5. The insulating, double-knit fabric of claim 1, wherein the first
knit layer comprises first yarns and the second knit layer
comprises second yarns, and wherein the first yarns and the second
yarns have a finer denier than the rows of fibers of the plurality
of intermediate fiber regions.
6. The insulating, double-knit fabric of claim 1, wherein the
plurality of fibers of the intermediate fiber regions comprise a
low melt fiber.
7. The insulating, double-knit fabric of claim 1, wherein the
plurality of fibers of the intermediate fiber regions comprise at
least one of a bi-component filament, a polyester blend, and a
polyamide.
8. The insulating, double-knit fabric of claim 1, wherein the
bi-component filament comprises modacrylic fiber and cellulosic
fiber.
9. The insulating, double-knit fabric of claim 1, wherein the first
knit layer and the second knit layer comprise a material selected
from the group consisting of polyester, polypropylene, nylon, wool,
cellulosic fibers, flame resistant fibers, modacrylic fibers, and
polyamide fibers.
10. The insulating, double-knit fabric of claim 1, wherein the
first knit layer and the second knit layer comprise a circular
knit.
11. A garment comprising the insulating, double-knit fabric of
claim 1.
12. A fabric article comprising the insulating, double-knit fabric
of claim 1.
Description
RELATED APPLICATIONS
[0001] The present application claims priority to U.S. Provisional
Application No. 62/557,950 filed Sep. 13, 2017, entitled "Power Air
Insulating Fabric," and to U.S. Provisional Application No.
62/692,012 filed Jun. 29, 2018, entitled "Power Air Insulating
Fabric" the entireties of which applications are hereby
incorporated herein by reference.
TECHNICAL FIELD
[0002] This invention relates to fabrics, and, more particularly,
to insulating performance fabrics, e.g. for wearing apparel, and
the like.
BACKGROUND
[0003] Performance fabrics manufactured for use in insulating
garments often include fleece fabric, i.e. fabric having a raised
or brushed fiber surface for improved insulation performance. The
surface of such fabrics is often formed of fleece, which is raised,
i.e. given relatively higher loft, by mechanical brushing. It has,
however, been recognized that the brushing process can often result
in broken fibers, which, over time, can work loose, potentially
resulting in microfiber pollution. Loss of fibers, e.g., during
washing, can also result in deterioration of insulation
performance. Further, it is recognized that broken fibers released
during washing can get into wastewater, causing pollution.
SUMMARY
[0004] Improved insulating performance fabrics have a knit, e.g., a
double-knit, body, formed with a traditional, relatively smooth,
outer surface, and an inner gridded surface with the form of
multiple fabric "bubbles" separated by a grid pattern of
intersecting grooves. Insulating performance fabrics, including
double-knit fabrics of this disclosure, may also be found in the
form, e.g., of garments comprising POLARTEC.TM. Power Air.TM.
performance fabrics, including insulating, double-knit fabrics,
e.g., in the form of fabric articles comprising POLARTEC.TM. Power
Air.TM. fabrics, formed, e.g., of insulating, double-knit fabric,
etc.
[0005] In one aspect of the disclosure, an insulating, double-knit
performance fabric includes a first knit layer, a second knit layer
coupled with the first knit layer, and a plurality of intermediate
fiber regions. The intermediate fiber regions contain a plurality
of fibers and positioned between the first knit layer and the
second knit layer. The plurality of intermediate fiber regions are
positioned in a plurality of air pockets formed by at least one of
the first knit layer and the second knit layer.
[0006] In certain implementations, the insulating, double-knit
performance fabric includes one or more of the following additional
features. The plurality of intermediate fiber regions may include a
plurality of regions of lofted fibers. The lofted fibers may be
un-napped, un-brushed and/or are not mechanically lifted. The
lofted fibers may be encapsulated in the plurality of air pockets
loose. The lofted fibers can extend in a direction having an
orthogonal component with respect to the at least one of the first
knit layer and the second knit layer. The lofted fibers may be
substantially parallel to first knit layer and the second knit
layer. The lofted fibers may be randomly positioned. The lofted
fibers may include microfibers. The plurality of regions of lofted
fibers may be spaced apart from one another. When the plurality of
regions of lofted fibers are spaced apart from one another this may
be achieved via a plurality of spaced rows separating them. The
insulating, double-knit performance fabric element can include at
least one braided tube positioned in and extending along at least a
portion of at least one space row in the plurality of spaced rows
separating the plurality of regions of lofted fibers from one
another. The braided tube comprises a monofilament composed, at
least in part, of a material that is distinct from the plurality of
fibers of the intermediate fiber. The first knit layer and the
second knit layer comprise a denier gradient such that the first
knit layer has a relatively finer denier than the second knit layer
or the second knit layer has a relatively finer denier than the
first knit layer. Each of the first knit layer and the second knit
layer may have a relatively finer denier than the plurality of
intermediate fiber regions. At least one of the first knit layer
and the second knit layer may form a smooth surface. At least one
of the first knit layer and the second knit layer may define a
plurality of windows. The plurality of windows can be positioned
over respective spaces of a plurality of spaces separating the
intermediate fiber regions from one another. The plurality of
intermediate fiber regions may be arranged in a gridded pattern.
The plurality of intermediate fiber regions may be arranged in a
plurality of rows. In some implementations, each of the
intermediate fiber regions include a plurality of rows of fibers
extending parallel to the at least one of the first knit layer and
the second knit layer. The plurality of fibers of the intermediate
fiber regions can include a low melt fiber. The plurality of fibers
of the intermediate fiber regions can include at least one of a
bi-component filament, a polyester blend, and a polyamide. The
bi-component filament can include modacrylic fiber and cellulosic
fiber. In some implementations, each of the first knit layer and
the second knit layer comprise the air pockets include the
plurality of intermediate fiber regions. The first knit layer and
the second knit layer may include a circular knit. The first knit
layer and the second knit layer can include a double raschel knit.
The plurality of intermediate fiber regions can include a plurality
of densities of lofted fibers. The intermediate fiber regions in
the plurality of intermediate fiber regions that are adjacent a
stitch coupling the first knit layer to the second knit layer can
have a lower density than intermediate fiber regions in the
plurality of intermediate fiber regions that are not adjacent to a
stitch coupling the first knit layer to the second knit layer.
[0007] In another aspect of the disclosure, a garment comprising an
insulating, double-knit performance fabric as described according
to an implementation disclosed herein is provided.
[0008] One aspect of the disclosure provides a method of
manufacturing an insulating, double-knit performance fabric. The
method includes knitting a first layer, knitting a second layer,
and positioning and/or attaching a plurality of fibers to at least
one of the first layer and the second layer. The plurality of
fibers positioned and/or attached as a plurality of separated fiber
regions. The method includes encapsulating the plurality of
separated fiber regions into a plurality of spaced apart air
pockets. The method includes attaching the first layer and the
second layer together so as to position the spaced apart air
pockets encapsulating the plurality of separated fiber regions
between the first layer and the second layer.
[0009] In certain implementations, the method of manufacturing an
insulating, double-knit performance fabric includes one or more of
the following processes. The method can include positioning a
braided tube in a space between the air pockets encapsulating the
plurality of separated fiber regions and between the first layer
and the second layer. The method can include exposing the braided
tube to heat to fuse a filament forming the braided tube together
inside the space. The method can include forming a plurality of
windows in at least one of the first layer and the second layer and
positioning the plurality of windows over and between the
pluralities of air pockets encapsulating the plurality of separated
fiber regions.
[0010] One aspect of the disclosure provides a method of
manufacturing an insulating, double-knit performance fabric
disclosed herein.
[0011] The details of one or more embodiments of the invention are
set forth in the accompanying drawings and the description below.
Other features, objects, and advantages of the invention will be
apparent from the description and drawings, and from the
claims.
DESCRIPTION OF DRAWINGS
[0012] FIG. 1 is a perspective view of a first (upper) element of a
POLARTEC.TM. Power Air.TM. fabric of this disclosure.
[0013] FIG. 2 is a perspective view of a second (lower) element of
a POLARTEC.TM. Power Air.TM. fabric of this disclosure.
[0014] FIG. 3 is a perspective view of a POLARTEC.TM. Power Air.TM.
fabric of this disclosure.
[0015] FIG. 4 is a perspective view of another embodiment of a
POLARTEC.TM. Power Air.TM. fabric of this disclosure.
[0016] FIG. 5 is a plan view of the POLARTEC.TM. Power Air.TM.
fabric of FIG. 4.
[0017] FIG. 6 is similar plan view of the POLARTEC.TM. Power
Air.TM. fabric of FIG. 4.
[0018] FIG. 7 is a first side view of the POLARTEC.TM. Power
Air.TM. fabric of FIG. 4.
[0019] FIG. 8 is a second side view of the POLARTEC.TM. Power
Air.TM. fabric of FIG. 4.
[0020] FIG. 9 is an example of a yarn of the POLARTEC.TM. Power
Air.TM. fabric of FIG. 4
[0021] FIG. 10 is a somewhat schematic side plan view of the
POLARTEC.TM. Power Air.TM. fabric of FIG. 4.
[0022] FIGS. 11A-11E show an embodiment of the POLARTEC.TM. Power
Air.TM. fabric with windows and an inlay and formed with circular
knit.
[0023] FIGS. 12A-12G illustrate embodiments of the POLARTEC.TM.
Power Air.TM. fabric with a solid back and face and formed with
double raschel.
[0024] FIGS. 13A-13D illustrate an embodiment of the POLARTEC.TM.
Power Air.TM. fabric with a solid back and an open face and formed
with double raschel.
[0025] Like reference symbols in the various drawings indicate like
elements.
DETAILED DESCRIPTION
[0026] The invention of the present disclosure, shown, e.g., in
FIGS. 1-4, provides a synthetic material that opens new worlds of
design possibilities in this important industry. In particular,
over the past half century, the process of developing performance
fabrics has continued to evolve and reshape. In this same time
span, our knowledge and understanding of how these synthetic
materials can potentially have adverse impact on the environment
has continued to grow. What's more, we have also begun to learn
more about how, over time, many of these synthetic products
continue to break down and shed small particulates, such as
microfibers. There is, however, a way to change how synthetic
fibers are designed, and thereby to reduce their longer term,
undesirable impact.
[0027] In response, this application introduces POLARTEC.TM. Power
Air.TM. synthetic fabric material 100 (see, e.g. FIGS. 1-3), a
revolutionary fabric that reduces microfiber shedding without
sacrificing desirable warmth-to-weight ratios. In one particular
embodiment, POLARTEC.TM. Power Air.TM. synthetic fabric material is
a single fabric structure knit into multiple components. For
example, referring to FIGS. 1-3, each of components 100, 102
encapsulates air around lofted fibers 118, thereby to contain body
heat in the manner of traditional insulation. The lofted fibers 118
are encapsulated via the knit structure of the fabric material 100.
In particular implementations, the regions of encapsulation are
more densely knitted to trap the lofted fibers. The dense knitting
is more dense on both the flat side as well as on the bubble side
of the encapsulated region, in particular implementations. However,
in an exemplary embodiment of the POLARTEC.TM. Power Air.TM.
synthetic fabric material, these loftier fibers 118 are no longer
exposed to outside elements or abrasive surfaces. Rather, these
loftier fibers 118 are secured inside each of the air pockets 106.
The result is a fabric 100 that has proven to shed 5.times. (i.e.
five times) less microfibers than standard fleece in laboratory
tests. Furthermore, the advantages of the POLARTEC.TM. Power
Air.TM. fabric design of the present invention do not stop at
microfiber retention, as its exposed smooth face 108 reduces
friction for less pilling, greater durability and easier layering
with other fabrics.
[0028] In addition, the fabric platform of the POLARTEC.TM. Power
Air.TM. fabric product creates entirely new categories of
performance knits. These performance knits are designed to provide
a wearer with relatively more warmth, and less shedding of
microfibers, thereby giving any outerwear application of the
POLARTEC.TM. Power Air.TM. fabric products even wider design
versatility, and with a negative impact (i.e. undesirable shedding
of microfibers) that has been reduced more than ever before.
POLARTEC.TM. Power Air.TM. fabric products thus hold "more than
just heat".
[0029] In one embodiment, the opposite exterior surfaces 110, 112
of the POLARTEC.TM. Power Air.TM. fabric 100 are smooth and soft,
while the respective opposed surfaces 114, 116 of the interior
construction have the form of a symmetrical grid pattern of air
pockets 106, which are found to provide enhanced encapsulation of
fibers and microfibers. In certain embodiments, the grid pattern of
air pockets may include spaces between the air pockets 106. The
POLARTEC.TM. Power Air.TM. fabric 100 is thus recognized as
"holding more than just heat," and provides a number of particular
features and advantages. These include, for example, high
warmth-to-weight ratio. They also include shedding of 5 times
(i.e., "5.times.") less microfibers, e.g., as compared to fleece
fabrics of similar utility and/or insulation performance. The
POLARTEC.TM. Power Air.TM. fabric is also versatile in a range of
design applications, including with smooth (outer) faces 110, 112
for easy layering. The disclosed fabrics, in preferred embodiments,
also exhibit, e.g., lasting durability, resistance to pilling,
and/or high breathability.
[0030] Also, by engineering a way to markedly enhance encapsulation
of synthetic lofted microfibers 118, POLARTEC.TM. Power Air.TM.
fabrics are changing how insulating fabrics will perform over their
lifetimes or how the insulating fabrics will retain their
performance and thereby increase their longevity. This new fabric
construction thus encases lofted fibers 118 within self-contained
air pockets 106. In certain implementations, the lofted fibers 118
are positioned in the air pocket randomly and/or are floating
within the air pocket. The air pockets 106 capture and release warm
air, while gaining added strength and support from the surrounding
knit structure. The structure 106 also serves as a barrier, which
prevents loose microfibers from shedding into the environment. The
two distinctly contrasting surfaces 106 and 112 of the POLARTEC.TM.
Power Air.TM. fabric 100 provide markedly wider design versatility,
e.g., as compared to most other insulation fabrics. Finally, the
symmetrical grid interior 114, 116 holds warmth, while the opposite
smooth surfaces 110, 112 reduce surface drag, thereby to reduce or
prevent pilling, and to allow easy layering with other
materials.
[0031] The components 100 and 102 are stitched together in
accordance with particular implementations. The components 100 and
102 are stitched together in a manner that reduces and/or avoids
stitching within the inlay (i.e. the air pockets 106 containing the
lofted fibers 118) to prevent the lofted fibers 118 from being
trapped or causing them to protrude through the exterior surfaces
110, 112. In certain implementations, the air pockets 106 along the
edge of the fabric or adjacent to stitching are provided with less
lofted fibers 118 than other air pockets away from an edge or not
adjacent to stitching securing the components 100 and 102 together
to reduce and/or eliminate trapping of lofted fibers and thereby
prevent and/or reduce lofted fibers from protruding through the
exterior surfaces 110, 112.
[0032] For example, referring again to FIGS. 4-9, a further
representative POLARTEC.TM. Power Air.TM. fabric product 10 is
shown having horizontal positioning (in the main view), with air
pockets 20 (seen at a macro level). The air pockets 20 provide
encapsulation of lofted fibers, and thermal retention, with
filtered microfibers (e.g., with approximately 5 times (i.e.,
"5.times.") less shedding of undesirable microfibers, e.g. as
compared to the shedding of microfibers by of comparable prior art
fabric products). Furthermore, the fabric of the present invention
typically has two distinct surfaces, including a symmetrical
gridded interior 16 and a smooth outer surface 14.
[0033] In use, a representative POLARTEC.TM. Power Air.TM. fabric
product is well suited for use in cold weather conditions and
activities, such as outdoor training, mountain trekking, in urban
environments, and is base installations, etc. In can also reduce,
or even make unnecessary, the putting on and removing of layers,
i.e., as often necessary for maintaining comfort, e.g. in changing
conditions and/or during varying degrees of exertion.
[0034] The improved, POLARTEC.TM. Power Air.TM. insulating fabric
10 has a double-knit body 12, formed with a first, traditional,
relatively smooth outside surface 14 and relatively high loft, grid
(or gridded) inside surface 16. POLARTEC.TM. Power Air.TM.
insulating fabric 10 is a double (weft) knit fabric designed in
such a way as to create a composite, three-layer construction,
including, but not limited to, relatively flat, smooth outer `face`
surfaces 14, an outer `backside` surface 16 with generally
hemispherical or somewhat irregular geometric-like raised areas 17
(FIG. 4), and a middle layer 19 (FIG. 5), which consists of
multifilament fibers contained between the two outer surface
regions 14, 16..TM.
[0035] The double-knit "bubbles" 18 and air spaces 20 of the inside
surface 16 of the POLARTEC.TM. Power Air.TM. fabric 10 provide an
insulating air space equivalent to traditional brushed grid fabric.
However, the POLARTEC.TM. Power Air.TM. insulating, double-knit
fabric is manufactured without a brushing step, which can at least
diminish the breaking of fibers, to eliminate (or at least reduce)
microfiber pollution, and also to reduce fiber loss in washing,
with resultant corresponding reduction in insulation performance.
The result is reduction, or elimination, of fiber pollution in
wastewater from washing. Additionally, there is a significant
reduction in the production of waste fibers during manufacturing
with the elimination of mechanical lifting via brushing or
knapping.
[0036] The design and construction of the improved POLARTEC.TM.
Power Air.TM. double-knit fabric 10 of the disclosure replaces the
middle layer of a brushed grid fabric.
[0037] The POLARTEC.TM. Power Air.TM. fabric, provided in different
gradients, in order to encourage advantageous movement of moisture
through the body of the fabric, or the insulating fabric, may be
formed of polypropylene yarns (recognized as a good water carrier,
i.e., polypropylene does not hold moisture), or yarns of these or
other materials, alone or in blend(s), may also be employed.
[0038] In some embodiments, the outer surface of at least some
yarns forming the fabric POLARTEC.TM. Power Air.TM. insulating,
double-knit fabric may define channels, e.g. the yarn has a
star-shape outer surface contour 24 (see FIG. 9), to
encourage/permit moisture movement, where desired.
[0039] The POLARTEC.TM. Power Air.TM. insulating, double-knit
fabric may be used, e.g., in insulating outdoor performance apparel
to provide a significantly reduced propensity to shed microfibers
during the life of the garment, while providing optimum comfort for
the wearer. The processing of this fabric excludes the use of
mechanical brushing or napping devices to increase insulation value
of the material for use in outdoor apparel. Referring to FIG. 10,
in one representative embodiment, the POLARTEC.TM. Power Air.TM.
insulating, double-knit fabric 12 is formed into a garment 20, e.g.
a shirt, which, for comfort in chilly or inclement weather, could
be worn as a mid-layer, in combination with and between a light
weight t-shirt or undershirt 22, worn against the wearer's skin, S,
and an outer, windbreaker-type jacket 24 worn on over the
POLARTEC.TM. Power Air.TM. insulating, double-knit fabric
garment.
[0040] Other performance features incorporated into the
POLARTEC.TM. Power Air.TM. insulating double-knit fabric include:
thermal insulating properties (measured as Clo value) achieved by
using fibers types and cross-sections that optimize thermal
insulation efficiency with minimal added fabric weight. Also,
moisture migration properties and fabric moisture retention are
managed in a manner to maximize comfort by utilization of fibers
with cross-sections that promote accelerated dry times and moisture
vapor transport rate. In particular embodiment, the lofted fibers
can be formed (e.g. geometrically or materially) to have a
particular gradient (e.g., denier) that causes moisture to flow in
a particular direction. In addition, pockets of air that add
insulation value and air movement (measured as air permeability)
for moisture management are created through the integration of
alternating raised surfaces 17 (FIG. 4) with the intersection of
back and face layers. Also, fiber coatings comprised of
polyurethane polymers are incorporated to promote fabric durability
(measured as "Martindale abrasion/pilling rating"). Finally, fiber
treatments comprised of silicon emulsions are incorporated to
modify fiber orientation within the raised fabric structure and
increase air volume, in certain implementations.
[0041] The POLARTEC.TM. Power Air fabrics thus provide multiple
desired qualities that may be described and summarized, for
example, as one or more of: "Warm more. Shed Less"; "Air Powered
Design"; "Holds More Than Heat"; "It's Time to Get Knit-Picky";
"Want to catch more than just Air?"; "Harness Your Heat"; "Put Some
Power in Your Insulation"; "Regulate Heat. Reduce Impact"; "The
Power of Air", etc.
[0042] As shown in the examples of FIGS. 11A-13D, the PowerAir.TM.
fabric can include various versions of the dual-surface double-knit
construction with various air encapsulation configurations.
[0043] FIGS. 11A-11E show an implementation of POLARTEC.TM. Power
Air fabric with windows and an inlay formed into the circular knit
construction. An inlayed fabric 1100 is illustrated in FIGS.
11A-11E. The inlayed fabric 1100 includes a plurality of windows
1106 formed in an outer layer 1101 of the fabric 1100. The inner
layer 1102, in contrast, does not include window inlays 1106. The
outer layer 1101 and the inner layer 1102 form a plurality of rows
or channels 1104 as shown in FIGS. 11C and 11D. The rows 1104 form
elongated air pockets housing intermediate fiber regions 1103
housing fibers 1107 positioned substantially parallel to the inner
layer 1102 and the outer layer 1101. In certain implementations,
the fibers 118 are floating within the channels 1104. The outer
knit layer 1101 is formed as a circular knit and the inner knit
layer 1102 is formed as a circular knit.
[0044] FIGS. 12A-12G illustrate POLARTEC.TM. Power Air.TM. fabric
with a solid back and face and formed with a double raschel. A
double raschel fabric 1200 is shown in FIGS. 12A-12G. The double
raschel fabric 1200 has a solid knit layer 1201 as well as a solid
knit layer 1202. The solid knit layer 1201 and solid knit layer
1202 may be composed of various materials that can include, but are
not limited to, polyester, polypropylene, nylon, wool, cellulosic
fibers, flame resistant fibers, modacrylic fibers, polyamide fibers
or other natural or synthetic fibers in whole or in part, blended
or unblended. The solid knit layers 1201 and 1202 encapsulate a
plurality of regions of lofted fibers 1203 between them. The lofted
fibers 1203 can be comprise polyester fibers, cotton fleeces,
rayon, polyamide, flame resistant fibers, but are not limited
thereto. The regions of lofted fibers 1203 are separated from one
another via spaces 1204, which comprise encapsulated air regions
without any lofted fibers disposed therein. The lofted fibers 1203
extend away from or substantially orthogonal (i.e., in a direction
having an orthogonal component) to the solid knit layers 1201 and
1202. The solid knit layers 1201 and 1202 form a denier gradient,
in particular implementations. In certain implementations the knit
layers 1201 and 1202 have a finer denier than the lofted fibers
1203, which assist with moving the water from one layer 1202, which
may be adjacent to a user's skin, to the lofted fibers 1203 and
then to the knit layer 1201 without retaining the water or moister
in the encapsulated lofted fibers 1203. Alternatively or
additionally, the knit layers 1201 and 1202 may have a different
denier with respect to one another. In certain implementations, the
regions of lofted fibers 1203 are configured in a grid array where
spaces separate each region from each other region. As demonstrated
in FIG. 12C, one of the knit layers 1201 can have a corrugated,
undulated, or other raised profile, while the opposing knit layer
1202 can have a planar or smoother profile. FIGS. 12E and 12F
further demonstrate in a cross-section view the spaces 1204
separating the lofted fibers 1203 from one another. In certain
implementations, the spaces 1204 may be extended lengthwise and
form an air channel running from one end of the fabric to another
end of the fabric. As demonstrated in FIGS. 12F and 12G, a braided
tube 1205 can be positioned in the elongated space 1204 between the
encapsulated lofted fibers 1203. The braided tube 1205 is flexible
and stretchable. The braided tube 1205 can include a monofilament,
which may be composed at least in part of a material that is
distinct from the lofted fibers 1203. The braided tube 1205
illustrated in FIG. 12G can be incorporated into any space
illustrated in other embodiments or implementations of the
POLARTEC.TM. Power Air.TM. fabric disclosed herein. In particular
embodiments, the braided tube 1205 is composed of nylon fibers. The
braided tube 1205 can be composed of other materials in accordance
with certain implementations. The braided tube 1205 can be composed
of a nylon fiber having a denier in the range of 20-100 denier, in
certain implementations. In particular, implementations, the denier
of the fiber forming the braided tube 1205 may be greater than 100
denier or less than 20 denier. The braided tube can be composed, at
least in part, from a monofilament or a multi-filament. The braided
tubing provides permits the fiber to be provided with additional
airspace with less weight and may be interspersed with regions of
the lofted fibers (e.g., lofted fibers 1203). The braided tubing
1205 provides air space that can increase insulation, yet provide
flexibility and elasticity to the fabric to prolong performance,
effectiveness, and durability. In certain implementations, the
braided tubing 1205 may be positioned between knit layers 1201 and
1202 in a fabric body provided without lofted fibers.
[0045] FIGS. 13A-13D illustrate an implementation of the
POLARTEC.TM. Power Air.TM. fabric with a solid back and an open
face and formed with double raschel. A double raschel knit fabric
1300 is illustrated in FIGS. 13A-13D having a first knit layer 1301
comprising a plurality of windows 1306 formed therein. In certain
implementations, the windows 1306 may have a constant size across
the fabric 1300. In certain implementations, the windows 1306 may
have variable size across the fabric 1300. The second knit layer
1302 does not include window inlays. The window inlays 1306 are
positioned over the space regions 1304 positioned between the
lofted fibers encapsulated in air pockets between the knit layer
1301 and 1302. The window inlays 1306 are positioned in spaces that
overlie air spaces between the knit layer 1301 and 1302 rather than
being positioned over the lofted fibers 1303. Accordingly, the
lofted fibers 1303 are retained encapsulated between the knit
layers 1301 and 1302, thereby preventing fiber loss and retaining
higher insulating performance levels for extended durations.
[0046] While various embodiments show the air/lofted microfiber
encapsulation pockets in a rectangular or square grid, various
embodiments can include other geometries, which can include
constant or varying pocket sizes. For example, the air/fiber
encapsulation pockets of lofted fibers may be larger and/or thicker
in a certain region of the fabric than in another region.
[0047] A number of embodiments of the invention are described
above. Nevertheless, it will be understood that various
modifications may be made without departing from the spirit and
scope of the invention. For example, synthetic materials described
above may be employed in industrial products, such as rubber tires,
plastics, etc. Accordingly, other embodiments are within the scope
of the following claims.
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