Patent Application
20070144221
(1) Field of the Invention
The present invention relates generally to textile products and, more particularly, to a 3-D fabric with domed shaped formed from a base “sandwich” material for providing cooling and/or insulation and improved stretch, compression resistance, decreased weight, and conformability and/or drape.
(2) Description of the Prior Art
U.S. Pat. No. 5,413,837 issued May 9, 1995 to Rock, et al. for Three-dimensional knit fabric teaches a three-dimensional knit or woven fabric that is permeable to water vapor but impermeable to liquid water is provided, including a first fabric layer, a second fabric layer and yarn interconnecting them, further including a barrier layer adhered to the outside surfaces, and the fabric being imperviously sealed.
U.S. Pat. No. 5,651,847 issued Jul. 29, 1997 to Loeffler for Double-face circular knit teaches a double face circular knit having two concentric lengths of knit web and an in-between spacer structure, wherein spacer threads are textured coarse-filament multifilament yarns, in combination with monofilament yarns.
U.S. Pat. No. 6,263,707 issued Jul. 24, 2001 to Miller, et al. for Opaque heat-moldable circular knit support fabrics having very high spandex content teaches a fabric and method including opaque heat-moldable circular knit fabrics having relatively high amounts of spandex material and other fibers to simultaneously provide maximum support and comfort to a wearer, wherein the fabric may be molded to the specifications of a wearer's body.
Prior art knitted spacer material commonly employs either warp-knitting or circular knitting techniques to produce a fabric having a predetermined thickness and bulk. However, the prior art knitted spacer materials typically have a relatively high weight, low stretch, and limited drape, since the fabric thickness and compressibility are factors that are generally optimized for a given application.
Thus, there remains a need for a 3-D fabric with domed shapes formed from a knitted spacer material having increased stretch and compression resistance, decreased weight, and improved drape as well as cooling and/or insulating properties.
The present invention is directed to a knitted stretch spacer material including the use of an elastomeric material such as SPANDEX for stretch and compression resistance without increasing weight, and improved conformability and/or drape. The present invention is further directed to a knitted spacer material further processed for particular applications, for example including mold-based forming and heat setting to provide a fabric having raised, shaped dimples or domes existing in a predetermined, repeated pattern wherein the domes protrude significantly above the fabric surface to provide a three-dimensional (3-D) channeled fabric for evaporative cooling and/or insulation, and comfort, in particular for applications as a layer of a garment, a liner material, or an underlayer beneath protective clothing or articles, such as, by way of example and not limitation, ballistic-protective wear, fire-protective wear, chemical- or radiation-protective wear, and the like. The present invention is still further directed to a method for making a knitted spacer material having high stretch, compression resistance, low weight, and improved drape or conformability with further processing steps to create the domed protrusions and garments or underlayers made therefrom.
Accordingly, one aspect of the present invention is to provide a knitted spacer material including a “sandwich” fabric having a face surface and a back surface in spaced apart relation with a body or filler portion constructed therebetween, and wherein the fabric is further processed to produce spaced apart, repeated patterned domes that form channels therebetween, producing a molded formed 3-D fabric. In embodiments where the fabric is used as a garment or portion of a garment, the fabric may further include a stretch yarn component for increased stretch and compression resistance of the material.
Another aspect of the present invention is to provide a 3-D dome-channeled knitted spacer material having different face and back surfaces, further including a secondary component, which may be applied as a coating, a lamination, and/or an infusion.
Still another aspect of the present invention is to provide a method for producing 3-D dome-channeled “sandwich” material, preferably formed from a knitted spacer material, in particular a circular knitted spacer material.
Still another aspect of the present invention is to provide a monofilament component fabric formed into a 3-D dome-channeled material for use as a garment or portion of a garment, such as a vest, for providing ventilation under protective equipment and/or clothing.
These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment when considered with the drawings.
In the following description, like reference characters designate like or corresponding parts throughout the several views. Also in the following description, it is to be understood that such terms as “forward,” “rearward,” “front,” “back,” “right,” “left,” “upwardly,” “downwardly,” and the like are words of convenience and are not to be construed as limiting terms.
Referring now to the drawings in general, the illustrations are for the purpose of describing a preferred embodiment of the invention and are not intended to limit the invention thereto.
The present invention provides a fabric having a face surface and a back surface forming a fabric plane, wherein the fabric is further processed to produce spaced apart, repeated patterned domes extending out of the fabric plane, the domes forming channels therebetween, producing a molded formed 3-D fabric for evaporative cooling and/or insulation as well as comfort, stretch, compression resistance, decreased weight, and improved drape, softness, and/or conformability, depending upon the yarn component and fabric properties.
In one embodiment, the fabric is formed from a knitted spacer material including a “sandwich” fabric having a face surface and a back surface in spaced apart relation with a body or filler portion constructed therebetween, and wherein the fabric is further processed to produce spaced apart, repeated patterned domes that form channels therebetween, producing a molded formed 3-D fabric, and methods of making the same. In embodiments where the fabric is used as a garment or portion of a garment, the fabric may further include a stretch yarn component for increased stretch and compression resistance of the material.
While
Furthermore, the 3-D fabric provides for “breathe-ability” for cooling and/or insulating. Most significantly, the 3-D domed shapes produce channels therebetween that allow for air flow for evaporative cooling and/or insulating via the air traveling or flowing in the channels and/or being trapped therebetween. Also, the fabric body itself may include a predetermined permeability depending upon the fabric construction, yarn density, yarn type, and whether or not coatings, films, or other treatments are applied (such as in the case of an all-monofilament base fabric body, wherein the fabric air permeability is relatively high).
In preferred embodiments of the present invention, a “sandwich” material having a first side and a spaced apart, parallel second side is used as the base fabric prior to dome formation via additional processing of the material. More preferably, a knitted spacer material is used as the base fabric. As best seen in
In one embodiment of the present invention, special yarns are selective used to provide enhanced functionality or added features to the fabric. By way of example but not limitation, a silver yarn may be used as part or all of one yarn system to provide natural antibacterial qualities. Alternatively, high strength yarns such as KEVLAR may be used for increased ballistic or penetration-resistance. Any fiber may be used within the “sandwich” fabric, depending upon the specific properties and performance requirements and the application of the fabric.
The body portion includes the third yarn system providing a compression resistant component substantially oriented in the z-direction or thickness direction of the material; while this component does extend in the x-direction and y-direction of the material as well, its main function is to provide the material properties in the z-direction or thickness by traversing between the face and back surfaces of the material, forming a zig-zag appearance when viewed from a side view as shown in
By way of specific design example,
In preferred embodiments, the knitted stretch spacer material includes a monofilament core wherein the yarn is between about 20 to about 400 denier, more preferably about 90 denier to optimize knittability, comfort, and compression-resistance.
In one embodiment, the knitted stretch spacer material is manufactured commercially by Beverly Knits, Inc. under the sample number BK 3595 Heavy at 22 oz/sq. yd, or under the sample number BK 3571 Light—19 oz/sq yd, having a non-laminated weights of 21 oz/sq. yd and 16.7 oz/sq. yd, respectively.
Furthermore, the material according to one embodiment of the present invention preferably has a thickness between about 2 mm to about 10 mm, more preferably between about 4 mm and about 6 mm prior to further processing to create the 3-D formed domed channeled material, which increases the overall thickness of the fabric by the dome height. Preferably, for garment, liner, underlayer applications and the like, a range of dome heights may be from at least equivalent to the fabric thickness, preferably greater, and more preferably 2× to 20×, which produces larger channels for cooling and/or insulating and/or providing additional body protection, such as penetration avoidance due to the protruding shape, stand-off or dome height. The drape of the fabric prior to molding or dome formation, as well as afterward, is further characterized as being a conformability factor, i.e., the capacity of the material or fabric to adapt to curvature, more particularly, to change direction and shape to conform to a user's body, in particular when the fabric is incorporated into a garment or a portion of a garment or other bodily coverage. The sandwich material or fabric described herein is uniquely suited to provide comfort due to drape and surface qualities, as well as shape retention, in particular substantial retention of the molded dome shape and dimensions to preserve the air channeling functionality when worn beneath other garments, specifically protective garments having substantial weight. By contrast, significantly, lighter weight, non-sandwich materials do not provide both benefits simultaneously.
Preferably, the knitted spacer material is formed of synthetic fibers in at least one of the yarn systems. Furthermore, in a preferred embodiment of the present invention, monofilament is used in at least one of the yarn systems, preferably in the third yarn system. Importantly, the monofilament component provides for additional improvement for compressibility and recovery as well as reducing the overall weight of the material. The compressibility and recovery properties of the present invention make it well-suited for impact dispersion applications.
By contrast, a prior art material manufactured from a warp-knit structure has significantly less stretch in the x- and y-directions than the present invention, as well as being thinner in the z-direction and being an overall heavier fabric per linear square unit. Note however, that some warp knitted materials may be manufactured at higher thicknesses, depending upon the specifications and/or desired characteristics of the fabric in a particular application, as is apparent to one of ordinary skill in the art.
While preferably, the present invention is a circular knit material, a warp-knit material may also be produced according to the present invention as set forth hereinabove without departing from the scope and spirit of the invention.
In another preferred embodiment, monofilament yarn components are interconnected to form a fabric that is further processed to create 3-D dome-channeled material for use as a garment or portion of a garment, such as a vest, for providing ventilation under protective equipment and/or clothing. Preferably, the monofilament is at least about 100 denier monofilament to provide sufficient stiffness and porosity for cooling and ventilation via channels between the 3-D fabric domes as well as through the plane of the fabric and domes directly, i.e., at substantially perpendicular direction to the channels. Thus, the fabric provides for breathability via fabric permeability as well as via channels to allow for evaporative cooling, or passive cooling. The fabric may be used as a liner for new garments and be interconnected at seams or other predetermined locations so as to provide a single garment, or as a liner that may be retrofit or attached to existing garments. In the latter case, the lining may be provided in the form of one or more panels that substantially fit under sections or portions of the garment, but are not made to exactly line or match the garment itself. These panels may be removably attachable in predetermined locations to the garment, for example by fasteners, hooks, buttons, hook-and-loop type fasteners, and the like, and combinations thereof.
Additional steps may be included for coupling or connecting (removably or permanently affixing) the fabric to a protective device or component such as a vest or garment lining, or cutting and sewing or otherwise connecting bonding the fabric segments to form a garment or a partial garment.
Other embodiments may include liners for back-packs, or other sporting equipment, such as protective guards or padding, including but not limited to soccer shin guards, football protective wear, helmets, knee pads, elbow pads, and the like.
Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. In particular, the knitted spacer material may function as a carrier or substrate, wherein additional processing provides additional and/or supplemental functionality not inherently present in the material itself. By way of example, the present invention may be further processed, e.g., by lamination or coating the fabric, where fabric permeability is not desirable or needed to be maximized. Additionally or alternatively, the knitted spacer material may be infused with another substance, such as a medication, for use as a bandaging material capable of releasing a medication at the location of its application, e.g., directly to a wound in a bandage application. Certain coatings can be applied to this spacer fabric to achieve different benefits and/or fabric characteristics or properties. Films applied to either side for moisture barriers or to enhance wicking. By way of example and not limitation, a phase change material may be applied to provide thermal management properties, such as temperature resistance, fire retardants, antimicrobial coatings or yarns may be used to manage, control, or limit bacterial growth. Seaming, sealing, or other edge processing, e.g, by way of example and not limitation, overedge sealing, ultrasonic or RF welding, or seaming, may also be advantageously included in additional processing, depending upon the application for the material.
Also, the 3-D fabric including a “sandwich” or spacer material may further function in some applications as a carrier of medicines like anti-clotting drugs etc. The fabric is capable of incorporating antibacterial products like silver or other chemical treatments. Also the fabric may have wicking treatments applied either topical or impregnated into the yarns. Any yarns can be used on either side including, aramid yarns like the commercially available KEVLAR, NOMEX, and others, natural fibers like cotton, wool, etc. man made fibers like polyester, nylon, polypropylene and others. The middle “sandwich” yarn can be made of other fibers also, nylon, polyester, polypropylene, all that can be formed with temperature and pressure.
All modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the present invention.
This section outlines a few design examples, not necessarily optimized, but illustrative of what can be done for a knitted spacer material according to the present invention and method of manufacturing the same. These design examples include the following:
In this preferred embodiment of the knitted spacer material as shown in
In the first yarn system direction, a Polyester yarn type of 40 denier was used in combination with a 40 denier spandex yarn; in the second yarn system, a Polyester yarn type of 40 denier was used in combination with a 40 denier spandex yarn; in the third yarn system, a Polyester yarn type of 177 denier monofilament was used in combination with a 70 denier polyester yarn. The machine set up included the following parameters: A double knit machine with a dial height variance up to 250 thousands separation from the cylinder, utilizing spandex feeder to plait spandex on the dial only and cylinder only feeds. Requirements include facilities to implement monofilament yarn into the knitting elements with controlled measurement of amount to minimize tension and improve knitting of monofilament yarn such that it does not poke thru the face and back of finished product.
Further information relating to the sample includes:
Laminated One Side—BK 3595 Heavy—22 oz/sq. yd, BK 3571 Light—19 oz/sq yd.
Unlaminated BK 3595 Heavy—21 oz/sq yd, BK 3571 Light—16.7 oz/sq yd.
Knits specs the Unlaminates at 22.9 and 18 oz respectively, so we start from different baselines.
Summary: Beneficial low spacer weight material.
Elasticity/Modulus (prior to dome channel formation):
As a matter of comparison to baseline:
One Side BK 3595 Heavy—elasticity and modulus are in the 30% and 150% range, respectively, of original unlaminated measurements. The original numbers were Desirable to Very Desirable for elasticity and Desirable for modulus. One Side BK 3571 Light—elasticity and modulus are in the 50% and 200% range, respectively, of original unlaminated measurements. The original numbers were Desirable for elasticity and Very Desirable for modulus.
Permeability
Water impermeability before and after bonding tests was Very Desirable.
Surprisingly, the introduction of 10% SPANDEX yarn in the yarn component system(s) required much experimentation with the machine set-up, wherein a setting of 17% was required for the material to be produced and reproduced consistently, providing the following material properties:
By increasing the spandex percentages and reducing the yarn sizes, the results created a fabric with the third yarn system in an almost vertical plane. This is most important to achieve the compression resistances of the require applications. This surprise allowed the reduction of monofilament used in the fabric to be decreased by almost 50%. The results thus produced fabrics of preferred weight variations, stretches and thickness.
BK 3595 Light; 17% spandex; 18.00 ounces per square yard weight; 100% length×150% width stretch, 6 mm thick.
BK 3595 Heavy; 17% spandex 22 ounces per square yard weight; 120% width×200% length stretch, 6 mm thick.
BK 3571 Light; 10% spandex; 18.00 ounces per square yard weight; 80% length×90% width stretch, 5 mm thick.
BK 3571 Heavy; 10% spandex 28 ounces per square yard weight; 90% width×160% length stretch, 6 mm thick.
Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. All modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the following claims.
This non-provisional utility patent application claims the benefit of one or more prior filed applications; the present application claims priority from U.S. provisional application Ser. No. 60/655,617 which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 60655617 | Feb 2005 | US |
