3-D fabric knitted stretch spacer material having molded domed patterns and method of making

Abstract

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.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS(S) [0001] 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.BACKGROUND OF THE INVENTION [0002] (1) Field of the Invention [0003] 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. [0004] (2) Description of the Prior Art [0005] 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...

AI Technical Summary

Benefits of technology

[0010] 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.

[0011] 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.

Problems solved by technology

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.

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