BACKGROUND
The present invention relates to a three-dimensional fabric structure and its manufacturing method, particularly to a sticky spacer fabric that has anti-slip and sticky properties to adhere more closely to the skin, while providing better breathability, heat and moisture permeability, comfort, excellent stretch and resilience, and its manufacturing method.
For the fabric structures used in daily wear clothing, such as shirts and pants, in order to provide wearers with a better wearing experience and comfortable sensation, the fabric structure needs to have good heat dissipation, breathability, sweat absorption, comfort, and lightness. In order to achieve these goals, various knitting methods, fiber arrangement structures, or different fiber materials have been developed for making clothes.
For the fabric structures used in some intimate clothing, such as women’s brassieres, besides the above characteristics, it is expected that women’s brassieres can have appropriate stickiness. Especially when wearing strapless brassieres, it is expected that they can have a tight-fit and appropriate stickiness to avoid slipping and embarrassing.
Currently, the so-called Spacer Fabrics (3D knit fabrics, also known as sandwich fabrics) on the market are difficult to meet the requirements for the above characteristics, so there is still room for improvement.
SUMMARY
To solve the above problems, an object of the present invention is to provide a sticky spacer fabric and its manufacturing method. The sticky spacer fabric of the present invention not only has slip-proof and sticky properties but also provides better breathability, heat and moisture permeability, comfort, excellent stretch and resilience, and environmental friendliness.
In order to achieve the above objectives, an embodiment of the present invention for a sticky spacer fabric comprises a first outer layer, an intermediate layer, and a second outer layer. The intermediate layer is interposed between the first and second outer layers and is interknit with the first and second outer layers. The first and second outer layers are formed by knitting, with at least one of them having a sticky surface formed by a thermoplastic elastic yarn using a knitting method, and the sticky surface is fully or partially exposed to the outside of the first or second outer layer.
In one embodiment of the present invention for a sticky spacer fabric, the first and second outer layers are plain stitch, purl stitch, jacquard stitch, or their combination. The first and second outer layers are formed by different knitting methods to create plain stitch, purl stitch, jacquard stitch, or their combination. In this way, the thermoplastic elastic yarn contained in the first and/or second outer layer can be fully or partially exposed to the outside of the first or second outer layer to form a sticky surface, and the intermediate layer can provide better moisture permeability.
In one embodiment of the present invention for a sticky spacer fabric, the length of the yarn in the intermediate layer varies with its position in the transverse direction, thereby forming a sticky spacer fabric with varying thickness.
On the other hand, another aspect of the present invention includes a method for manufacturing a sticky spacer fabric, comprising knitting a sticky spacer fabric including a first outer layer, a second outer layer, and an intermediate layer, scouring the sticky spacer fabric, preheating the sticky spacer fabric, dyeing the sticky spacer fabric, and thermally setting the sticky spacer fabric to melt the thermoplastic elastic yarn and adhere it to the second yarn. One of the first and second outer layers is formed by two types of yarn, including a first yarn and a second yarn, knit together, with the first yarn being a thermoplastic elastic yarn used to form a sticky surface, and the sticky surface is fully or partially exposed to the outside of the first or second outer layer. The intermediate layer is interposed between the first and second outer layers and is interknit with the first and second outer layers. By the final thermal setting step, the thermoplastic elastic yarn is melted and adhered to the second yarn, and the finished sticky spacer fabric can prevent yarn loops from falling-off and avoid breakage.
On another aspect of the present invention, a garment made of a sticky spacer fabric is provided. The sticky spacer fabric includes a first outer layer, an intermediate layer, and a second outer layer. The intermediate layer is interposed between the first and second outer layers and is interknit with the first and second outer layers. The first and second outer layers are formed by knitting, with at least one of them having a sticky surface formed by a thermoplastic elastic yarn using a knitting method, and the sticky surface is fully or partially exposed to the outside of the first or second outer layer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the knitting structure of an embodiment of the sticky spacer fabric of the present invention;
FIG. 2 is a schematic view of the knitting structure of the first outer layer of one embodiment of the sticky spacer fabric of the present invention;
FIG. 3 is a schematic view of the knitting structure of the second outer layer of one embodiment of the sticky spacer fabric of the present invention;
FIG. 4 is a schematic view of the knitting structure of the intermediate layer of one embodiment of the sticky spacer fabric of the present invention;
FIG. 5 is a schematic view of the knitting structure of the second embodiment of the first outer layer of the sticky spacer fabric of the present invention;
FIG. 6 is a schematic view of the knitting structure of the second embodiment of the second outer layer of the sticky spacer fabric of the present invention;
FIG. 7 is a schematic view of the knitting structure of the second embodiment of the intermediate layer of the sticky spacer fabric of the present invention;
FIG. 8 shows an example of underwear made using the sticky spacer fabric of the present invention;
FIG. 9 is a schematic view of the knitting structure of the third embodiment of the first outer layer of the sticky spacer fabric of the present invention;
FIGS. 10 and 11 are schematic views of the knitting structure of the third embodiment of the second outer layer of the sticky spacer fabric of the present invention, respectively;
FIG. 12 shows an example of a predetermined jacquard pattern; and
FIG. 13 is a side view of the structure of the sticky spacer fabric of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
First, referring to FIG. 1, a side view of the knitting structure of an embodiment of the sticky spacer fabric of the present invention is shown.
As shown in FIG. 1, the sticky spacer fabric of the present invention includes a first outer layer 10, an intermediate layer 30, and a second outer layer 20. The intermediate layer 30 is interknit between the first outer layer 10 and the second outer layer 20 and is preferably knitting-made from monofilament yarns. The first outer layer 10 and the second outer layer 20 are formed by knitting, for example, by warp knitting or weft knitting. The sticky spacer fabric of the present invention can be made by circular weft knitting, which is a type of weft knitting. As a preferred embodiment of the sticky spacer fabric of the present invention, as shown in FIG. 2, one of the first outer layer 10 and the second outer layer 20 is formed by knitting two types of yarns, including a first yarn 41 and a second yarn 42. The first yarn 41 is a thermoplastic elastic yarn used to form a sticky surface, and the sticky surface is partially or fully exposed on the outside of the first outer layer 10 or the second outer layer 20. The thermoplastic elastic yarn is preferably spandex yarn or thermoplastic polyurethane (TPU) yarn, and the yarn material of the second yarn 42 is selected from polyester fibers, nylon fibers, cotton, spandex, and thermoplastic polyurethane (TPU) fibers.
In one embodiment of the present invention, the first outer layer 10 and the second outer layer 20 are formed by different knitting methods, such as plain stitch, purl stitch, jacquard stitch, or any combination thereof. Thus, the thermoplastic elastic yarn contained in the first outer layer 10 and/or the second outer layer 20 can be entirely or partially exposed to the outside of the first outer layer 10 or the second outer layer 20 to form the sticky surface, and the intermediate layer 30 can provide better heat and moisture permeability. Using the present invention’s sticky spacer fabric to manufacture clothing that fits closely to the body, the sticky surface can adhere tightly to the skin and provide appropriate stickiness, preventing the garment from slipping.
Please refer to FIGS. 2 to 4, which illustrate an exemplary first embodiment of the present invention’s sticky spacer fabric. FIG. 2 shows a schematic drawing of the first outer layer 10 formed by the first yarn 41 and the second yarn 42 fed to the first knitting needle 51 at an angle of 10-70 degrees from each other through a yarn feeder and knitted together, wherein the first outer layer 10 is a plain stitch, and the first yarn 41 serves as the face yarn of the first outer layer 10 to form the sticky surface, and the second yarn 42 serves as the bottom yarn of the first outer layer 10. In other words, the sticky surface formed by the first yarn 41 is entirely exposed to the outside of the first outer layer 10. FIG. 3 shows a schematic drawing of the second outer layer 20 of the present invention’s sticky spacer fabric, wherein the first yarn 41 and the second yarn 42 are fed to the second knitting needle 52 at an angle of 10-70 degrees from each other through a yarn feeder and knitted together to form the second outer layer 20, which is a plain stitch, and the first yarn 41 serves as the face yarn of the second outer layer 20 to form the sticky surface, and the second yarn 42 serves as the bottom yarn of the second outer layer 20. In other words, the sticky surface formed by the first yarn 41 is entirely exposed to the outside of the second outer layer 20. FIG. 4 shows that the intermediate layer 30 is formed of monofilament yarn knitted by the collaboration of the first set of knitting needle 51 and the second set of knitting needle 52, and the intermediate layer 30 is interknit between the first outer layer 10 and the second outer layer 20. Ideally, after the knitting of the sticky spacer fabric is completed, it can undergo thermal setting in the subsequent processing. By heating the sticky spacer fabric to melt the thermoplastic elastic yarn and adhere it to the second yarn 42, it can prevent the loops of the fabric from falling off and avoid yarn breakage. It is best to heat at a temperature between the softening point and melting point of the thermoplastic elastic yarn to soften the thermoplastic elastic yarn and achieve the effect of melting and adhesive with the second yarn 42.
Please refer to FIGS. 5 to 7, which illustrate the second embodiment of the present invention’s sticky spacer fabric in an exemplary manner. FIG. 5 shows the first yarn 41 and the second yarn 42 being alternately fed to the first set of knitting needles 51 at an angle of 10-70 degrees from each other to form the first outer layer 10. The first outer layer 10 shown in FIG. 5 is a purl stitch, with the first yarn 41 and the second yarn 42 alternating as the face yarn or bottom yarn of the first outer layer 10 according to the default knitting pattern. Thus, some of the first yarn 41 acts as the face yarn of the first outer layer 10 according to the default knitting pattern to form the sticky surface. FIG. 6 shows the first yarn 41 and the second yarn 42 being alternately fed to the second set of knitting needles 52 at an angle of 10-70 degrees from each other to form the second outer layer 20. The second outer layer 20 shown in FIG. 6 is a purl stitch, with the first yarn 41 and the second yarn 42 alternating as the face yarn or bottom yarn of the second outer layer 20 according to the default knitting pattern. Thus, some of the first yarn 41 acts as the face yarn of the second outer layer 20 according to the default knitting pattern to form the sticky surface. FIG. 7 shows that the monofilament yarn is knitted by the collaboration of the first set of knitting needles 51 and the second set of knitting needles 52 to form the intermediate layer 30, which is located between the first outer layer 10 and the second outer layer 20 and interknit with the first outer layer 10 and the second outer layer 20. Similarly, the knitted sticky spacer fabric undergoes thermal setting in the subsequent production process. By heating the sticky spacer fabric, the thermoplastic elastic yarn melts and adheres to the second yarn 42, preventing the loops of the fabric from falling off and avoiding yarn breakage. The temperature for heating is preferably between the softening point and the melting point of the thermoplastic elastic yarn, so that the thermoplastic elastic yarn softens and achieves the effect of melting and adhesive with the second yarn 42.
FIG. 8 exemplarily shows underwear made using the present invention’s sticky spacer fabric. The sticky spacer fabric with purl stitch made according to FIGS. 6 and 7 is used, with some of the first yarn 41 knitted according to the default knitting pattern. Therefore, the sticky first yarn 41 forms part or all of the sticky surface at the default position outside the first outer layer 10 or the second outer layer 20, while the second yarn 42 forms a non-sticky surface at the remaining positions outside the first outer layer 10 or the second outer layer 20. Therefore, the appropriate position of the underwear can fit tightly with the skin and have appropriate adhesion to avoid slipping and embarrassing. The intermediate layer 30 is interknit between the first outer layer 10 and the second outer layer 20, becoming a sandwich-like structure. This type of textile or fabric, made using three-dimensional knitting methods, is also commonly known as sandwich fabric. Additionally, the intermediate layer 30 can provide better moisture permeability and heat dissipation. Clothing made using the sticky spacer fabric of the present invention can provide the wearer with a comfortable experience and excellent stretch and resilient properties, as well as being environmentally friendly.
Please refer to FIGS. 9 to 12 for an illustrative third embodiment of the present invention’s sticky spacer fabric, which uses jacquard stitch instead of purl stitch to achieve partial exposure of the thermoplastic elastic yarn. In the third embodiment, FIG. 9 shows that the first outer layer 10 is a plain stitch formed by the first yarn 41 and the second yarn 42 passing through the first set of knitting needles 51. FIGS. 10 and 11 show that the second outer layer 20 is a jacquard knitting formed by the first yarn 41 and the second yarn 42 passing through the second set of knitting needles 52, where the first yarn 41 is a thermoplastic elastic yarn, such as spandex or thermoplastic polyurethane (TPU) yarn, and the second yarn 42 is a general yarn, preferably selected from a group consisting of polyester fiber, nylon fiber, cotton, spandex, and TPU. According to the predetermined jacquard pattern, the first yarn 41 and the second yarn 42 are separately formed into courses by a warp knitting method to form the jacquard stitch. FIG. 12 shows that specific knitting needles and sequences in the second set of knitting needles 52 are selected based on the predetermined jacquard pattern. In the exemplary embodiment shown in FIGS. 10 and 11, the first, second, fifth, sixth, and seventh needles in the second set of knitting needles 52 are selected to knit the first yarn 41, forming the course structure shown in FIG. 10 in a row. The second yarn 42 is fed into the third and fourth needles in the second set of knitting needles 52, forming the course structure shown in FIG. 11 in the same row. It should be noted that the selection of knitting needles for knitting the first yarn 41 and the second yarn 42 is complementary, meaning that the positions of the courses formed by the first yarn 41 and the second yarn 42 in the same row are complementary. In one embodiment, a circular weft knitting machine can be used to form the jacquard stitch of the third embodiment. In one embodiment, two out of three circular weft knitting methods, such as knit, tuck, and miss, can be periodically used to form courses. In one embodiment, three circular knitting methods knit, tuck, and miss can be periodically used to form courses.
One embodiment of the present invention includes making a sticky spacer fabric with the required transparency by selecting yarns of appropriate yarn density and knitting density, in other words, making the sticky spacer fabric and the clothes made from it present the desired transparency effect. Preferably, the yarn density of the yarns used to make the first outer layer 10 and the second outer layer 20 is 5-40 deniers, and the line density of the yarns used to make the intermediate layer 30 is 10-50 deniers. Preferably, the CPI (Course Per Inch) of the first outer layer 10 and the second outer layer 20 is 50-80, and the WPI (Wale Per Inch) of the first outer layer 10 and the second outer layer 20 is 20-50.
FIG. 13 is a schematic side view of the structure of the sticky spacer fabric of the present invention, showing a sticky spacer fabric with variable thickness. In one embodiment of the present invention, the intermediate layer 30 is knitted with monofilament yarns, and by changing the length of the yarns in the intermediate layer 30, a sticky spacer fabric with variable thickness can be realized. FIG. 13 shows an exemplary range, where the length of the yarns in the intermediate layer 30 of the sticky spacer fabric changes with its position in the transverse direction, thus forming a sticky spacer fabric with variable thickness.
Another aspect of the present invention includes the manufacturing method of the above sticky spacer fabric, comprising the following steps: knitting the above sticky spacer fabric containing the first outer layer 10, the second outer layer 20, and the intermediate layer 30; scouring the sticky spacer fabric; preheating the sticky spacer fabric to stabilize the size of the yarns and fibers as well as the form of the fabric, preferably pre-heating the sticky spacer fabric at 150-2200 for about 30-180 seconds; dyeing the sticky spacer fabric; and finally thermal setting the sticky spacer fabric, melting the thermoplastic elastic yarns and adhering them with the second yarn 42. The thermal setting temperature is preferably between the softening point and melting point of the thermoplastic elastic yarns to soften the thermoplastic elastic yarns and achieve the effect of adhesive with the second yarn 42. The sticky spacer fabric is preferably heated at 150-2200 for about 30-180 seconds.
Although the use of two types of yarns to make the first outer layer 10 and/or the second outer layer 20 of the sticky spacer fabric has been disclosed in the above embodiments of the present invention, in other feasible embodiments of the present invention, the first outer layer 10 and/or the second outer layer 20 of the sticky spacer fabric may include more than two types of yarns, but at least one of them is a thermoplastic elastic yarn, and the other yarns may include colored yarns and yarns of other materials. In other embodiments of the present invention, the yarns used to form the first outer layer 10 and/or the second outer layer 20 may include thermoplastic elastic yarns and other yarns, and the intermediate layer 30 may include monofilament yarns.
Although the present invention has been disclosed through the embodiments described above, it is not intended to limit the scope of the invention. Those skilled in the art to which the invention pertains should understand and be able to implement the invention within the spirit and scope of the invention. Accordingly, slight modifications and embellishments can be made without departing from the spirit and scope of the invention. Therefore, the scope of the patent protection of the present invention should be defined by the claims attached to this application.
Patent Application
20230349080
