Patent Application
20220307168
This invention relates to an open, breathable fabric suitable for a wide range of uses and to garments fabricated in whole or in part from such fabrics.
Textile fabrics can be created in many forms—woven, non-woven, braided and knitted. Knitted fabric structures, which can be formed by warp knitting or weft knitting of varying types, are highly flexible, conformable and can be designed to have high porosity. In warp knitting, yarns follow a zigzag pattern along the long direction of the fabric, forming wales. These yarns are looped together to form courses. The properties and applications of the knitted textile structure can be tailored based on factors including the types of machines, structures, stitches, yarns and needle sizes used during the warp knitting process.
Tricot warp knitting enables production of fabrics having low density and a high profile. The warp yarns pass through one to four guide bars using shogging and swinging motions—typically electronically controlled through a Human-Machine Interface (HMI), or remotely networked through CAD knitting software. Servo motor-controlled warp beam let-off and fabric take-up systems provide precise tension control throughout the fabric formation process. Infinite pattern repeat functionality supports the design of highly engineered fabrics with regions of specialized physical and mechanical properties where desirable.
In the particular embodiment shown in this application by way of example, the fabric has a net-like mesh construction that has a thickness dimension that provides an air space between the skin of a wearer and, for example, an outer garment that overlies the fabric. One such specific application is for use as an undergarment worn beneath heavy, densely-fabricated clothing of the type worn by, for example, military, law enforcement, public safety and fire fighting personnel. The inventive fabric provides a “standoff” that allows air flow, heat dispersion and moisture evaporation between the undergarment and an outer garment. The fabric is lightweight and possesses several characteristics that make it particularly adapted for the uses described above, among others. These characteristics include no melt and no drip flame resistant performance, superior warmth resulting from a unique open construction that creates air pockets of insulation next to the skin, as well as anti-microbial, wicking and quick drying performance. The fabric is easily condensed into a small volume for packaging, shipment and storage.
It is therefore an object of the present invention to provide a fabric that possesses characteristics including a net-like mesh construction that has a thickness dimension that provides an air space between the skin of a wearer and an outer garment.
It is another object of the invention to provide a fabric that is intended for use as an undergarment worn beneath heavy, densely-fabricated clothing of the type worn by, for example, military, law enforcement, public safety and fire fighting personnel.
It is another object of the invention to provide a fabric that includes no melt and no drip flame resistant performance, superior warmth resulting from a unique open construction that creates air pockets of insulation next to the skin, and that has anti-microbial, wicking and quick drying performance.
It is another object of the invention to provide a fabric that is easily condensed into a small volume for packaging, shipment and storage.
It is another object of the invention to provide garments according to various suitable designs that have the characteristics described and defined in this application.
These and other objects and advantages of the invention are achieved by providing a fabric that is warp knitted with a low density and a high profile.
According to one aspect of the invention, a knitted mesh fabric is provided and includes a plurality of longitudinally and transversely extending warp-knitted yarns constructed of synthetic, or synthetic and natural, fibers forming an open, planar framework, the open, planar framework including air transmission openings defined by a yarn/void ratio of between 40-55 percent; and the fabric further characterized by air permeability of at least 1000 Pa (0.15 Psi) between an underlying surface and an overlying surface in relation to the fabric.
According to another aspect of the fabric invention, the fabric is constructed of yarns formed of synthetic fibers.
According to another aspect of the fabric invention, the synthetic fibers are modacrylic fibers and rayon fibers.
According to another aspect of the fabric invention, the rayon fibers are flame retardant rayon fibers.
According to another aspect of the fabric invention, the fabric is constructed of yarns formed of about 78 percent modacrylic fibers and about 22 percent flame retardant rayon fibers.
According to another aspect of the fabric invention, the air transmission openings are diamond-shaped in relation to a lengthwise side edge and a widthwise side edge of the fabric.
According to another aspect of the fabric invention, the fabric has an uncompressed thickness of between 0.0198 in. (0.5 mm) and 0.0242 in. (0.6 mm).
According to another aspect of the fabric invention, the fabric is constructed of yarns formed of synthetic fibers and natural fibers.
According to another aspect of the fabric invention, the synthetic fibers are rayon and nylon fibers and the natural fibers are wool fibers.
According to another aspect of the fabric invention, the rayon fibers are flame retardant rayon fibers.
According to another aspect of the fabric invention, the fabric is constructed of yarns formed of about 50 percent flame retardant rayon, about 30 percent wool and about 20 percent nylon fibers.
According to another aspect of the fabric invention, the warp knit fabric is a tricot warp knit fabric.
According to another aspect of the fabric invention, the fabric has stretch in the width (course) direction of between about 25 percent and 35 percent.
According to another aspect of the fabric invention, the fabric has a weight of between about 3.5 oz/yd2 (118 g/m2) and about 4.3 oz/yd2 (146 g/m2).
According to another aspect of the invention, a garment constructed of a knitted mesh fabric is provided, wherein the fabric is constructed of a plurality of longitudinally and transversely extending warp-knitted yarns constructed of synthetic, or synthetic and natural, fibers forming an open, planar framework. The open, planar framework includes air transmission openings defined by a yarn/void ratio of between 40-55 percent. The garment is further characterized by the fabric having an air permeability of at least 1000 Pa (0.15 Psi) between an underlying skin surface and an overlying surface in relation to the fabric.
According to another aspect of the garment invention, the garment is an undergarment selected from the group consisting of an upper body undergarment for a human, a lower body undergarment for a human and a full body garment for a human.
According to another aspect of the garment invention, the fabric is constructed of yarns formed of synthetic fibers.
According to another aspect of the garment invention, the synthetic fibers are modacrylic fibers and rayon fibers.
According to another aspect of the garment invention, the rayon fibers are flame retardant rayon fibers.
According to another aspect of the garment invention, the fabric is constructed of yarns formed of about 78 percent modacrylic fibers and about 22 percent flame retardant rayon fibers.
According to another aspect of the garment invention, the air transmission openings are diamond-shaped in relation to a lengthwise side edge and a widthwise side edge of the fabric.
According to another aspect of the garment invention, the fabric has an uncompressed thickness of between 0.0198 in. (0.5 mm) and 0.0242 in (0.6 mm)
According to another aspect of the garment invention, the fabric is constructed of yarns formed of synthetic fibers and natural fibers.
According to another aspect of the garment invention, the synthetic fibers are rayon and nylon fibers and the natural fibers are wool fibers.
According to another aspect of the garment invention, wherein the rayon fibers are flame retardant rayon fibers.
According to another aspect of the garment invention, the fabric is constructed of yarns formed of about 50 percent flame retardant rayon, about 30 percent wool and about 20 percent nylon fibers.
According to another aspect of the garment invention, the warp knit fabric is a tricot warp knit fabric.
According to another aspect of the garment invention, the fabric has stretch in the width (course) direction of between about 25 percent and 35 percent.
According to another aspect of the garment invention, the fabric has a weight of between about 3.5 oz/yd2 (118 g/m2) and about 4.3 oz/yd2 (146 g/m2).
According to another aspect of the garment invention, the air transmission openings are diamond-shaped in relation to a lengthwise side edge and a widthwise side edge of the fabric of the invention the fabric is a tricot warp knit fabric.
According to another aspect, of the garment invention the fabric is constructed of a combination of synthetic and natural fiber yarns.
According to another aspect of the garment invention, the fabric is constructed of synthetic fiber yarns.
According to another aspect of the garment invention, the fabric is constructed of modacrylic and rayon fiber yarns.
According to another aspect of the garment invention, the fabric is constructed of modacrylic, rayon and wool fiber yarns.
The present invention is best understood when the following detailed description of the invention is read with reference to the accompanying drawings, in which:
Referring now to the Figures,
Referring to
The combination of features of fabric 40, including the weight, number, size and shape of the openings 44 and thickness provide a high profile “standoff” between the skin of a wearer and an outer garment. This feature provides for enhanced air and moisture ventilation, allowing perspiration to evaporate more rapidly, and also provides at the same time a physical barrier between the skin and an outer garment, which may have a rough, abrasive inner surface texture.
The fabric 40 may be constructed of synthetic, or synthetic and natural, fiber yarns having the characteristics set out by way of example in Table A, below.
Fabrics within the scope of the invention may have differing characteristics from those as described in Table A, which is for purposes of example only. By reference to the ruler shown in
Referring again to
A mesh fabric and garments constructed from such fabrics according to the invention has been described with reference to specific embodiments and examples. Various details of the invention may be changed without departing from the scope of the invention. Furthermore, the foregoing description of the preferred embodiments of the invention and best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation, the invention being defined by the claims.
This utility patent application claims priority to the Provisional Application No. 63/167,159 filed on Mar. 29, 2021, the contents of which are incorporated by reference into this application.
| Number | Date | Country | |
|---|---|---|---|
| 63167159 | Mar 2021 | US |
