The present invention relates generally to textile fabrics and, more particularly, to multi-layer knitted fabric constructions that provide the ability to cool skin below a current temperature of the skin for a longer duration primarily when wetted but secondarily in a dry state.
Previous wet-activated cooling fabrics have used woven and double knit constructions using absorbent yarns which have moisture absorbing properties. A first layer, located next to the skin, provides a sustained cooling effect. However, such fabrics generally quickly dry out and/or warm up to the skin temperature of the user, negating any cooling effect. Therefore, a need exists for a multi-layer cooling fabric employing more advanced yarns and construction techniques which can provide a sustained cooling effect for a greater amount of time.
The present invention relates generally to textile fabrics and, more particularly, to multi-layer knitted fabric constructions that provide the ability to cool skin below a current temperature of the skin for a longer duration, primarily when wetted, but secondarily in a dry state.
Warp Knit Construction
As shown in
The layers of cooling fabric 100 depicted in
A first layer 104 of the cooling fabric 100, to be warn against the skin 102, is preferably formed of a combination of a stretchable synthetic yarn and an evaporative yarn. Suitable stretchable synthetic yarns include, but are not limited to, spandex, lycra or elastane. Preferably, spandex is used in the construction of cooling fabric 100. A cross-section of a single filament of a stretchable synthetic yarn, such as spandex, is depicted in
The evaporative yarn of first layer 104, together with the spandex, creates hydrophobic & hydrophilic channels for perspiration to enter the absorbent center of cooling fabric 100 while also allowing the chilled (e.g., 60° F.) center to provide conductive cooling against skin 102 (e.g., at an average skin temperature of 93.2° F.) as shown by the arrows near skin 102. The evaporative yarn of first layer 104 is preferably a nylon or polyester yarn having a unique cross-section (as seen in
The second layer 106 of cooling fabric 100 is formed from a highly absorbent yarn designed to absorb and hold moisture that is wicked from skin 102 by first layer 104. The high absorbance of the second layer 106 is also important to provide a cooling effect to skin 102. That is, because the second layer 106 is highly absorbent, it is able to retain a greater quantity of cooled water when wetted while still providing the ability to absorb wicked moisture.
Second layer 106 is preferably formed from a conjugated bi-component polyester and nylon yarn with a special star-shaped cross-section (the star-shaped cross-section is formed as the result of a treatment applied after cooling fabric 100 is knitted) as depicted in
The third layer 108 of cooling fabric 100 is formed from a yarn designed to transport moisture and provide a cool touch. The third layer 108 allows the moisture trapped in second layer 106 to evaporate into the ambient air and also allows ambient air to move into second layer 106 to cool the center of cooling fabric 100. A cross-section of a single filament of a yarn suitable for use in third layer 108 is depicted in
The cooling effect for cooling fabric 100 follows the principles of evaporative cooling. This principle details that water must have heat applied to change from a liquid to a vapor. Once evaporation occurs, this heat from the liquid water is taken due to evaporation resulting in cooler liquid. Once the cooling fabric 100 is wetted with water and preferably wringed to remove excess water, snapping or twirling in the air is a recommended process as it helps facilitate and expedite the moisture movement from the second layer 106, where water is stored, to the outer evaporative layers 104 and 108, where water evaporation occurs. Snapping or twirling in the air also increases the evaporation rate and decreases the material temperature more rapidly by exposing more surface area of the material to air and increased air flow. More specifically, the cooling fabric 100 functions as a device that facilitates and expedites the evaporative process.
Once the temperature of the remaining water in the outer evaporative layer 108 drops through evaporation, a heat exchange happens within water through convection, between water and fabric through conduction, and within fabric through conduction. Thus, the temperature of cooling fabric 100 drops. The evaporation process further continues by wicking water away from the layer 106 to layers 104 and 108 until the stored water is used up. The evaporation rate decreases as the temperature of cooling fabric 100 drops. The temperature of cooling fabric 100 drops gradually to a certain point where equilibrium is reached between the rate of heat absorption into material from environment and heat release by evaporation.
Once the wetted cooling fabric 100 is placed onto one's skin, cooling energy from the cooling fabric 100 is transferred through conduction. After the cooling energy transfer has occurred, the temperature of the cooling fabric increases to equilibrate with the skin temperature. Once this occurs, the wetted cooling fabric 100 can easily be re-activated by the snapping or the twirling method to again drop the temperature.
The various views depicted in
The four-yarn combination utilized in cooling fabric 100 allows for more absorption of water to occur while transporting water efficiently through cooling fabric 100 to create an evaporative cooling effect which increases the conductive cooling effect of cooling fabric 100. Further benefits of cooling fabric 100 include:
Next, with reference to
Examples of warp knit tricot 4-bar will be described herein. A first example for warp knit tricot 4-bar construction, depicted in
Preferably, bar 1 is a 35 Denier/24 filament nylon fully drawn yarn; bar 2 is a 50 Denier/48 filament conjugated polyester/nylon bi-component fully drawn yarn; bar 3 is a 75 Denier/36 filament polyester draw textured yarn; and bar 4 is a 40 Denier spandex. This configuration results in a fabric having a density of 100-600 g/m2, but more preferably 160-400 g/m2. The combined multi-layer cooling fabric 100 resulting from this stitch is depicted in
The yarn Deniers and filament counts used on bars 1-4 can be varied using the following ranges:
Another embodiment of cooling fabric 100 uses the following 4-bar knitting stitch and yarn combination:
Bar 1-1-0/2-3 (evaporative yarn such as ASKIN)
Bar 2-1-2/1-0 (absorbent yarn such as MIPAN XF)
Bar 3-0-1/2-1 (evaporative yarn such as ASKIN)
Bar 4-1-0/1-2 (elastic yarn such as Spandex).
In this stitch configuration, bar 1 is a 45 Denier/24 filament polyester fully drawn yarn; bar 2 is a 50 Denier/48 filament polyester and nylon conjugated fully drawn yarn; bar 3 is a 75 Denier/36 filament polyester draw textured yarn; and bar 4 is a 40 Denier spandex.
In both knitting stitch examples, bars 1 and 3 are cool touch/quick dry/absorption materials as have already been described. The Qmax for these yarns is greater than 0.140 W/cm2 on the face side and 0.120 W/cm2 on the back side of the material which indicates a cooling touch effect as has already been described. The wet Qmax for these yarns is greater than 0.280 W/cm2 on face side and 0.180 W/cm2 on back side. Bar 2 is a conjugated highly absorbent yarn (MIPAN XF) which has a wicking rate and a wicking distance more than twice that of cotton of equivalent density. The spandex yarn provides hydrophobic properties, provides stretch properties, and a draping effect.
Additional Performance Yarn
An embodiment of the present invention is the use of other performance yarns to enhance evaporative and absorbency effects. Specifically, for the yarns listed in layers 104 and 108, other evaporative yarns with additional performance properties can be added, blended, or twisted with the evaporative yarns to intensify the cooling effect of fabric 100. Possible additional evaporative yarns include, but are not limited to, the following:
Finishing Practices
In addition to normal textile finishing practices, an embodiment of the present invention includes applying extra finishing practices before or after construction of cooling fabric 100 which impart added cooling power, duration, temperatures and other cooling performance properties when the cooling fabric 100 is wetted to activate. The following provides examples of additional finishing practices suitable for use with cooling fabric 100. Combinations of the following methods may also be employed.
Fabric Construction & Yarn Positions
A variety or combination of any of the following described constructions can impart added cooling power, duration, and lower temperatures when the cooling fabric is wetted to activate.
Seamless and Hosiery Construction and Yarns
Seamless constructions require the use of a single yarn feed (which is typically a combination of nylon or polyester plus spandex) during construction. This single feed can be a single yarn or composed of multiple yarns during construction. In a first described embodiment, described is a multi-filament yarn construction that can be used in seamless constructions (e.g., for hosiery) that provides the same cooling effect as cooling fabric 100 described with reference to
The core 702 is either double covered (
When yarn 700 is used in a seamless construction, the evaporative yarn, located in covering 704, rests against the skin of the user and it wicks moisture to the core 700. The moisture can then leave the fabric through covering 704 which is also exposed to the air (i.e., because it surrounds the core 700 on all sides). In this way, yarn 700 can be used to provide a similar layering effect to that of cooling fabric 100 depicted in
An example of a seamless knit construction utilizing yarn 700 is depicted in
Other methods can also be used to form yarn 700 as depicted in
Seamless knit constructions have the advantage of being tubular and can be used to create unique patterns to impart added or lessened cooling zones within the material. The yarns shown in
In other embodiments, the yarn used in the seamless or hosiery construction can be a single feed utilizing any combination of the yarns containing the filaments shown in
The present invention has been described with respect to various examples. Nevertheless, it is to be understood that various modifications may be made without departing from the spirit and scope of the invention as described by the following claims.
The present application is a continuation application of International Application No.: PCT/US2017/035734, filed Jun. 2, 2017, the entire contents of which are hereby incorporated by reference in their entirety, and which claims priority to U.S. Provisional Patent Application Ser. No. 62/345,321, filed Jun. 3, 2016, the entire contents of which are hereby incorporated by reference in their entirety.
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Number | Date | Country | |
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Parent | PCT/US2017/035734 | Jun 2017 | US |
Child | 16100939 | US |