Spacer fabrics with one or more lengths of tie yarns

Abstract

Aspects of the present disclosure relate to a spatial fabric comprising a first layer, a second layer, and a plurality of tie yarns interconnecting the first layer and the second layer. The spatial fabric further comprises one or more isolated regions in which the first layer and a portion of the length of the tie yarns are absent.

Description

[0001] This application is a divisional application of the invention patent application with application date of March 28, 2019, application number 201980035523.0, and invention name “Spacer fabric with one or more lengths of tying yarns”. Technical Field

[0002] Aspects herein relate to unitary three-dimensional spacer fabrics having one or more lengths of tie yarns. Background Art

[0003] Conventional spacer fabrics comprise two layers of fabric connected together by tie yarns that are looped with the yarns in the fabric layers and with each other. Summary of the Invention

[0004] One aspect of the present disclosure relates to a unitary, three-dimensional spacer fabric comprising a first region comprising: a first layer having a continuous weave construction; a second layer and a third layer, the third layer comprising a first monofilament tie yarn interconnecting the first and second layers; and a second region comprising a second layer, wherein the plurality of monofilament tie yarns are absent in the second region. The first layer comprises a first yarn type comprising cationic dyeable polyethylene terephthalate (CD PET).

[0005] Another aspect of the present disclosure relates to a method of treating a spacer fabric comprising a first layer, a second layer, and a third layer, the first layer having a continuous woven construction, the third layer comprising a first monofilament tie yarn of a plurality of monofilament tie yarns interconnecting the first and second layers, the method comprising: applying an alkaline cellulolytic agent to one or more second regions of the spacer fabric, wherein after applying the alkaline cellulolytic agent to the one or more second regions, the plurality of monofilament tie yarns are absent from the one or more second regions.

[0006] Another aspect of the present disclosure relates to a fabric comprising: a first face oriented in a first direction and a second face oriented in a second direction opposite the first direction; a first region comprising a spacer fabric comprising a first woven layer, a second woven layer, and a third layer, the third layer comprising a monofilament tie yarn interconnecting the first and second woven layers; in the first region, the first woven layer comprises a first face of the fabric oriented in the first direction; and a second region bounded by the first region, the first region forming a boundary around the second region, wherein within the boundary, the monofilament tie yarn is absent from the fabric, and the second woven layer comprises the first face of the fabric and the second face of the fabric. The first woven layer is formed from a first yarn type comprising cationic dyeable polyethylene terephthalate (CD PET).

[0007] Another aspect of the present disclosure relates to a method of treating a spacer fabric, comprising: weaving a fabric comprising a spacer fabric having a first woven layer, a second woven layer, and a third layer, the third layer comprising a monofilament tie yarn interconnecting the first woven layer and the second woven layer, wherein, in the spacer fabric, the first woven layer comprises a first side of the fabric oriented in a first direction and the second woven layer comprises a second side of the fabric oriented in a second direction; and removing the first woven layer and the monofilament tie yarn from an area of ​​the fabric based on the application of an alkaline cellulolytic agent, wherein, in the area, the first woven layer and the monofilament tie yarn are not present in the spacer fabric and the second woven layer comprises the first side of the fabric.

[0008] Another aspect of the present invention relates to a method for treating a spacer fabric, wherein the spacer fabric includes a first layer, a second layer, and a third layer, wherein the first layer has a mesh structure, the mesh structure having a plurality of integrally formed holes, the first layer having at least a first outer surface defining a first outer surface plane; the second layer having at least a second inner surface; and the third layer including a first multifilament tie yarn of a plurality of multifilament tie yarns interconnecting the first layer and the second layer, the method comprising: applying an alkaline fiber decomposing agent to the first layer of the spacer fabric in one or more predetermined areas, wherein after the alkaline fiber decomposing agent is applied to the one or more predetermined areas, the plurality of multifilament tie yarns have variable lengths in the one or more predetermined areas. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Examples of various aspects of the present invention are described in detail below with reference to the accompanying drawings, in which:

[0010] Figure 1 A cross-sectional view of a spacer fabric is shown to illustrate common structural features of woven spacer fabrics according to aspects herein;

[0011] Figure 2showing a perspective view of a first surface of a spacer fabric according to aspects herein;

[0012] Figure 3 Shown according to various aspects of this invention Figure 2 A perspective view of the spacer fabric showing the second opposing surface;

[0013] Figure 4 Shown according to various aspects of this invention Figure 2 and 3 A cross-sectional view of a spacer fabric;

[0014] Figure 5 Shown according to various aspects of this invention Figure 2-4 a spacer fabric having an area with a portion of the first layer and a portion of the length of the tie yarn removed;

[0015] Figure 6 Shown according to various aspects of this invention Figure 5 A cross-sectional view of a spacer fabric;

[0016] Figure 7 shows a cross-sectional view of a second alternative spacer fabric according to aspects herein;

[0017] Figure 8 According to aspects of this invention, Figure 7 A perspective view of a spacer fabric having a portion of the first layer and an area of ​​tie yarn removed;

[0018] Figure 9 Shown according to various aspects of this invention Figure 8 A cross-sectional view of a spacer fabric;

[0019] Figure 10 shows a cross-sectional view of a third alternative spacer fabric according to aspects herein;

[0020] Figure 11 Shown according to various aspects of this invention Figure 10 A perspective view of a spacer fabric having a portion of the first layer and an area with loop portions of the tie yarn removed;

[0021] Figure 12 Shown according to various aspects of this invention Figure 11 A cross-sectional view of a spacer fabric;

[0022] Figure 13 Shown is an incorporation of various aspects of the present invention Figure 10-12 Garments made of spacer fabrics; and

[0023] Figure 14 A flow chart illustrating a method of forming a spacer fabric as described herein, according to aspects herein, is shown. DETAILED DESCRIPTION

[0024] The subject matter of the present invention is described in detail herein to satisfy statutory requirements. However, the description itself is not intended to limit the scope of the present disclosure. On the contrary, the inventors have anticipated that the claimed or disclosed subject matter may also be embodied in other ways, in conjunction with other current or future technologies, to include steps or combinations of steps different from those described in this document. Furthermore, although the terms "step" and / or "box" may be used herein to refer to different elements of the method employed, these terms should not be interpreted as implying any particular order between the various steps disclosed herein unless the order of the various steps is explicitly stated.

[0025] At a high level, aspects herein relate to fabrics and garments formed from the fabrics. In one aspect, the fabric comprises a three-dimensional (3-D) spacer fabric having a first region, the first region having a first layer, a second layer, and a third layer, the first layer comprising, for example, a mesh construction having integrally formed apertures, the second layer comprising, for example, a continuous woven construction, and the third layer interconnecting the first and second layers. In various aspects, the third layer comprises one or more multifilament tie yarns (also referred to as spacer yarns) interconnecting the first and second layers. The fabric further comprises at least a second region in which the first layer and varying lengths of the tie yarns are absent or removed. The result is a fabric having the aesthetics and functionality of a plush or velvet-type fabric (having pile of varying lengths) in the second region, while the remaining regions of the fabric have the aesthetics and functionality of a spacer fabric.

[0026] In another aspect, the fabric includes a 3-D spacer fabric having a first region, the first region having a first layer, a second layer, and a third layer. The first layer comprises a continuous braid construction braid, for example, using a fine denier (about 20 denier to about 24 denier) yarn type; the second layer comprises, for example, a continuous braid construction; and the third layer interconnects the first and second layers. In various aspects, the third layer comprises one or more monofilament tie yarns interconnecting the first and second layers. The fabric also includes at least a second region in which the first layer and the monofilament tie yarns located in the second region are absent or removed. The result is a fabric that includes only the second layer in the second region, while the remaining regions of the fabric have the aesthetics and functionality of a spacer fabric.

[0027] In yet another aspect, the fabric comprises a 3-D spacer fabric having a first region, the first region having a first layer, a second layer, and a third layer, the first layer comprising a continuous braid construction braid, for example, using a fine denier (about 20 denier to about 24 denier) yarn type, the second layer comprising, for example, a continuous braid construction, and the third layer interconnecting the first and second layers. In various aspects, the third layer comprises one or more multifilament tie yarns interconnecting the first and second layers. The fabric also comprises at least a second region in which the first layer and the "loop" portions of the tie yarns located in the second region are absent or removed. The result is a fabric that has the aesthetics and functionality of a plush or velvet-type fabric (with a generally uniform pile length) in the second region, while the remainder of the fabric has the aesthetics and functionality of a spacer fabric.

[0028] Continuing from a functional perspective, the fabric regions comprising the first, second, and third layers exhibit properties typically associated with spacer fabrics, such as cushioning properties, thermal insulation (e.g., hot air is trapped or stored in the space between the first and second layers), temperature regulation, and air permeability levels that are typically greater than typical woven constructions, such as single-sided or double-sided knits. The second regions described herein (e.g., regions where the first layer and the tie yarn or a portion of the length of the tie yarn is absent or removed) typically exhibit higher air permeability than the regions of the fabric comprising the first, second, and third layers. When the fabric is incorporated into a garment, the second regions described herein can be positioned on the garment to correspond to high heat or sweating areas of the human body when the garment is in a worn configuration. Because these regions have a higher degree of air permeability than the rest of the fabric, air from the external environment may more easily enter the garment at these regions, thereby helping to cool the wearer, and heat and / or moisture generated by the wearer may more easily escape the garment at these regions.

[0029] Aspects of this paper further relate to a method for forming a fabric with the above-mentioned properties. In some aspects, the method may include applying an alkaline fiber decomposing agent to a fabric comprising a first layer formed of one or more cationic dyeable polyethylene terephthalate (CD PET) yarns, a second layer formed of non-CD PET yarns, and a third layer comprising one or more multifilament or monofilament CD PET yarns interconnecting the first and second layers. More specifically, the alkaline fiber decomposing agent is applied to the first layer of the fabric in one or more predetermined areas. In various aspects, application can be carried out via a digital printing process, an inkjet printing process, a screen printing process, a roller printing process, etc. The alkaline fiber decomposing agent is configured to degrade at least a portion of the length of the CD PET yarn in the first layer and the CD PET multifilament or monofilament tie yarn in the third layer when heat is applied.

[0030] Continuing, fabric-related parameters, such as the type of weave construction and / or the use of multifilament or monofilament tie yarns, can be selected to achieve specific aesthetic and functional effects. For example, selecting a continuous weave construction using fine denier CD PET yarn for the first layer can facilitate penetration of the alkaline cellulolytic agent through the first layer to the CD PET monofilament or multifilament tie yarns of the third layer. When CD PET monofilament yarn is selected for the third layer, the result is the removal of the continuously woven first layer and the monofilament tie yarns, leaving only the second layer in the fabric areas where the alkaline cellulolytic agent was applied. When CD PET multifilament yarn is selected for the third layer, the result is the removal of the continuously woven first layer and the "loop" portion of the multifilament tie yarns, creating a plush or raised effect in the fabric areas where the alkaline cellulolytic agent was applied.

[0031] In another example, a mesh structure can be selected for the first layer, and a CD PET multifilament tie yarn can be selected for the third layer. This selection allows the alkaline fiber decomposing agent to penetrate more deeply through the pores in the mesh structure and less deeply through the remainder of the mesh structure (i.e., the non-pore portions). The result is that a portion of the length of the first layer and the CD PET multifilament tie yarn is removed in areas adjacent to the pores in the first layer, and loop portions of the CD PET multifilament tie yarn are removed in areas corresponding to the non-pore portions of the mesh structure. This creates a tie yarn of variable length in the area where the alkaline fiber decomposing agent is applied.

[0032] Parameters associated with the alkaline cellulolytic agent can also be adjusted to facilitate the removal of the CD PET yarns in the first layer and some or all of the CD PET monofilament or multifilament yarns in the third layer. For example, the type of alkaline cellulolytic agent, the amount of alkaline cellulolytic agent applied to the fabric, the concentration of the alkaline cellulolytic agent, etc., can be controlled during the application step to remove varying lengths of the CD PET multifilament or monofilament tie yarns. Similarly, parameters associated with the heat application step, such as time and temperature, can be controlled to remove varying lengths of the CD PET multifilament or monofilament tie yarns. The non-CD PET yarns in the third layer are unaffected by the alkaline cellulolytic agent, thereby maintaining the integrity or continuity of the third layer after application and subsequent removal of the alkaline cellulolytic agent.

[0033] Thus, aspects herein relate to an integral, three-dimensional spacer fabric comprising a first region comprising: a first layer having a mesh-like configuration with a plurality of integrally formed apertures, the first layer having at least a first outer surface defining a first outer surface plane; a second layer having at least a second inner surface; and a third layer comprising a first multifilament tie yarn of a first plurality of multifilament tie yarns interconnecting the first and second layers, the first multifilament tie yarn having a first length measured between the second inner surface and the first outer surface plane in the first region. The spacer fabric further comprises a second region comprising a second multifilament tie yarn of a second plurality of multifilament tie yarns in the second and third layers, wherein the second multifilament tie yarn comprises a second length measured between the second inner surface and distal ends of the second multifilament tie yarn in a direction extending toward the first outer surface plane, the second length being less than the first length.

[0034] Aspects of the present disclosure also relate to a garment comprising a unitary three-dimensional spacer fabric, the spacer fabric comprising a first region comprising: a first layer having a mesh-like configuration, the first layer having at least a first outer surface defining a first outer surface plane; a second layer having at least a second inner surface; and a third layer comprising a first multifilament tie yarn of a plurality of multifilament tie yarns interconnecting the first and second layers, the first multifilament tie yarn having a first length measured between the second inner surface and the first outer surface plane in the first region. The spacer fabric also comprises a second region comprising a second multifilament tie yarn of a second plurality of multifilament tie yarns in the second and third layers, wherein the second multifilament tie yarn comprises a second length measured between the second inner surface and distal ends of the second multifilament tie yarn along a direction extending toward the first outer surface plane, the second length being less than the first length.

[0035] Aspects herein further relate to a unitary three-dimensional spacer fabric comprising a first region comprising: a first layer having a continuous woven construction, the first layer having at least a first outer surface defining a first outer surface plane; a second layer having at least a second inner surface; and a third layer comprising a first multifilament tie yarn of a first plurality of multifilament tie yarns interconnecting the first and second layers, the first multifilament tie yarn having a first length measured between the second inner surface and the first outer surface plane in the first region. The three-dimensional spacer fabric further comprises a second region comprising a second multifilament tie yarn of a second plurality of multifilament tie yarns in the second and third layers, wherein the second multifilament tie yarn comprises a second length measured between the second inner surface and distal ends of the second multifilament tie yarn along a direction extending toward the first outer surface plane, the second length being less than the first length.

[0036] Aspects herein further relate to a unitary three-dimensional spacer fabric comprising a first region comprising: a first layer having a continuous braid construction, the first layer having at least a first interior surface defining a first interior surface plane; a second layer having at least a second interior surface; and a third layer comprising a first multifilament tie yarn of a first plurality of multifilament tie yarns interconnecting the first and second layers, the first multifilament tie yarn having a first length measured between the second interior surface and the first interior surface plane in the first region. The three-dimensional spacer fabric further comprises a second region comprising a second monofilament tie yarn of a second plurality of monofilament tie yarns in the second and third layers, wherein the second monofilament tie yarn comprises a second length measured between the second interior surface and distal ends of the second monofilament tie yarn along a direction extending toward the first interior surface plane, the second length being less than the first length.

[0037] As used herein, positional terms used to describe a garment, such as "front," "back," "front side," "back side," "upper," "lower," "inward-facing surface," "outward-facing surface," and the like, are relative to the garment as worn by a wearer in an upright position as shown and described herein. As used herein, the term "spacer fabric" is intended to encompass both warp-knitted spacer fabrics and weft-knitted spacer fabrics known in the fabric art. Spacer fabrics are typically formed by interweaving a first layer and a second layer of fabric using at least one tie yarn. More specifically, each of the first layer and the second layer can be woven separately, and the tie yarn(s) are used to connect the first layer and the second layer. For example, the tie yarn may have a "loop" portion extending into each of the first layer and the second layer, wherein the loop portion interloops with yarns in the first layer and the second layer to connect the two layers. The distance between the first layer and the second layer can be varied by, for example, varying the length of the tie yarn extending between the first layer and the second layer. For example, the distance between the first layer and the second layer can be from about 1 mm to about 20 mm, depending on the length of the tie yarn extending between the first layer and the second layer.

[0038] Because each of the first and second layers are knitted separately, each of the first, second, and third layers can be knitted with different yarns and / or different yarn types. However, within a given layer (e.g., the first, second, or third layer), a particular yarn may extend through at least a portion of that layer. Because the first and second layers can be knitted independently of each other using different yarn types, the two layers can have different knit configurations (e.g., mesh or continuous) and exhibit different properties.

[0039] When describing, for example, yarn, the term "terephthalate polymer-based" refers to yarn having filaments and / or fibers formed from terephthalate polymers, and includes, for example, polyethylene terephthalate (PET), poly-1,4-cyclohexene-dimethylene terephthalate (PCDT), polybutylene terephthalate (PCT), and polytrimethylene terephthalate (PTT). Aspects of the present invention also contemplate the use of cationic dyeable (CD) PET yarns. As used herein, CD PET yarns may include PET yarns that have been modified during the polymerization process to produce anionic sites (e.g., sulfonic acid groups). As used herein, the term "non-CD PET yarn" refers to PET yarns that have not been modified as described herein. The term "non-CD PET yarn" may also refer to other non-PET yarn types, such as polyamide yarns, cotton yarns, elastomer yarns, etc. The term "polyamide-based" when describing yarns refers to yarns having filaments and / or fibers formed from any long-chain synthetic polyamide. The term "elastomeric" when describing yarns, as used herein, generally refers to a type of yarn that can provide a maximum stretch under load of greater than about 200%, with some elastomeric yarns providing a maximum stretch of about 400%, before returning to its unstretched state when the load is removed. Examples of elastomeric yarn types include Lycra, rubber, etc.

[0040] As used herein, the term "mesh" refers to a fabric having a woven construction in which openings are formed by changing the weaving process used to form the fabric (e.g., by dropping or transferring stitches). As used herein, the term "continuous woven construction" refers to a fabric having a continuous woven face without integrally formed or designed openings (e.g., without intentional dropped or transferred stitches). Examples include single-sided woven construction, half-warp woven construction, double-sided needle woven construction, etc. As used herein, the term "multifilament yarn" refers to a yarn having two or more filaments in a single yarn strand, while the term "monofilament" as used herein refers to a yarn formed from a single filament.

[0041] Similarly, as used herein, the term "unitary" refers to a fabric having at least one textile element (e.g., yarn, thread, filament, or fiber) extending between different regions of the fabric. For example, with respect to the spacer fabrics described herein, the term "unitary spacer fabric" may refer to a spacer fabric having continuous yarns or tie yarns extending through different regions of the first and / or second layers of the spacer fabric, and tie yarns extending through at least different regions of the third layer of the spacer fabric and portions of the first and second layers. To describe this with respect to a woven construction, the term "unitary spacer fabric" may refer to a spacer fabric having yarns from one region of the first and / or second and / or third layers of the spacer fabric interlooped with one or more woven loops in another region. This may be in contrast to a panel-type construction, in which two or more separate materials are joined by securing the edges or surfaces using, for example, stitching, bonding, adhesives, etc., such that there is no continuity of yarn or textile element between the two materials.

[0042] Now turn Figure 1 According to aspects of the present disclosure, a spacer fabric 10 is shown. The spacer fabric 10 is provided to illustrate features associated with the tie yarns of the different layers of the woven spacer fabric 10 and to illustrate various reference planes that may be described with respect to various aspects of the present disclosure. The spacer fabric 10 includes a first layer 1 having a first inner surface 6 defining a first inner surface plane 11 extending in the x-direction and the y-direction, and a first outer surface 7 defining a first outer surface plane 15 extending in the x-direction and the y-direction. As further described below, according to aspects of the present disclosure, the first layer 1 can include a continuous woven construction or a mesh woven construction, wherein the continuous woven construction or the mesh is formed using CD PET yarn.

[0043] Continuing, spacer fabric 10 also includes a second layer 2 having a second inner surface 8 defining a second inner surface plane 12 extending in the x- and y-directions, and a second outer surface 9 defining a second outer surface plane 13 extending in the x- and y-directions. According to aspects herein, second layer 2 can include a continuous woven construction formed using non-CD PET yarn. In some aspects, the non-CD PET yarn can include PET yarn, polyamide yarn, cotton yarn, elastomeric yarn, and the like.

[0044] The spacer fabric 10 also includes a third layer 3 comprising one or more tie yarns 14 interwoven with the first and second layers 1, 2. Although only one tie yarn 14 is shown for the third layer 3, it is contemplated herein that more than one tie yarn may be used to form the third layer 3. The portions of the tie yarns 14, designated by reference numerals 4 and 5 and shown in phantom to indicate that they are generally hidden, represent those areas of the tie yarns 14 that are interlooped with the yarns forming the first and second layers 1, 2, respectively. As used throughout this disclosure, the terms "loop" or "loop portion" when referring to a tie yarn refer to the portion of the tie yarn that extends into and loops with the yarns of the first and second layers 1, 2. To describe differently, a loop portion of a tie yarn is the portion of the tie yarn that does not extend between the first and second inner surface planes 11, 12 of the spacer fabric 10. Aspects herein contemplate that the third layer 3 is formed using CD PET monofilament or multifilament yarn.

[0045] Now refer to Figure 2 and Figure 3 , a perspective view of a first spacer fabric 100 is shown according to aspects of the present disclosure, wherein the spacer fabric 100 is shown from two opposing surfaces. The spacer fabric 100 includes a first layer 110 ( Figure 2 ), a second layer 112 ( Figure 3 ) and a third layer 114 positioned primarily between the first layer 110 and the second layer 112. Figure 2 , the first layer 110 can be considered to extend in a first x,y plane, as indicated by the arrows. Similarly, and the tube Figure 3 The second layer 112 can also be considered to extend in a second x,y plane, where the second x,y plane is offset from but substantially parallel to the first x,y plane.

[0046] In one aspect, the first layer 110 comprises a mesh-like woven construction having a plurality of integrally formed pores 116. The pores 116 can be woven to have one or more sizes, and the pore size can be variable or uniform across the surface of the first layer 110. Figure 4 As better shown, the apertures 116 extend through the thickness of the first layer 110 so as to place it in fluid communication with the third layer 114 and with the space formed between the first and second layers 110 , 112 .

[0047] In various aspects, a first yarn type comprising CD PET can be used to form the first layer 110. The yarn forming the first layer can have a denier of about 25D to about 35D, about 27D to about 33D, about 29D to about 31D, or about 30D. As used herein, the term "about" means within ±10% of the specified value.

[0048] about Figure 3 In various aspects, second layer 112 comprises a continuous woven construction without integrally formed holes. In various aspects, second layer 112 can be formed using at least one second yarn type, including, for example, a polyamide. More specifically, the polyamide includes caprolactam (also known as nylon 6). However, as described above, second layer 112 can also be formed using other non-CD PET yarns, such as conventional PET, cotton, etc. Second layer 112 can further be formed using an elastomeric yarn type to provide stretch properties to spacer fabric 100. More specifically, second layer 112 can be formed using a caprolactam yarn that is covered or wrapped around an elastomeric core; the elastomeric core can include spandex. The covered yarn can have a denier of approximately 70D to approximately 80D, approximately 73D to approximately 78D, approximately 74D to approximately 76D, or approximately 75D.

[0049] In various aspects, the third layer 114 includes one or more multifilament tie yarns 115 that are interwoven with the first and second layers 110, 112 to interconnect these layers. Figure 4 To further explain, the non-loop portion of the tie yarn 115 can have a predetermined length measured between the inward-facing surface of the first layer 110 and the inward-facing surface of the second layer 112, so that the first layer 110 and the second layer 112 are separated by a predetermined amount (e.g., approximately 4 mm).

[0050] Continuing, the distance between adjacent tie yarns 115 (e.g., measured in the x-direction and the y-direction) can be adjusted to provide varying degrees of compressibility of the spacer fabric 100. For example, the spacing can be decreased (e.g., more tie yarns per given area) to reduce the compressibility of the spacer fabric 100, and the spacing can be increased (e.g., fewer tie yarns per given area) to increase the compressibility of the spacer fabric 100. Thus, although the spacer fabric 100 may be more compressible than the spacer fabric 100, the spacer fabric 100 may be more compressible than the spacer fabric 100. Figure 2 and Figure 3 In the embodiment of the present invention, the tie yarns 115 are shown as being spaced apart a certain distance, but it is contemplated herein that other spacing configurations may be used. In addition, although the tie yarns 115 are shown as extending between the first layer 110 and the second layer 112 in a vertical orientation such that they are generally perpendicular to the first layer 110 and the second layer 112, it is contemplated herein that the tie yarns 115 may include other orientations other than vertical. For example, when the spacer fabric 100 is in an uncompressed state (i.e., a resting state), the tie yarns 115 may be positioned generally perpendicular to the first layer 110 and the second layer 112, or may be tilted up to, for example, ±70 degrees from the vertical.

[0051] Continuing, in various aspects, the tie yarns 115 can be formed from a third yarn type, wherein the third yarn type includes CD PET. The yarns forming the third layer can have a denier of about 15D to about 25D, about 17D to about 23D, about 19D to about 21D, or about 20D. Each tie yarn 115 can include about 18 to about 30 filaments per tie yarn, about 20 to about 28 filaments per tie yarn, about 23 to about 25 filaments per tie yarn, or about 24 filaments per tie yarn.

[0052] Figure 4 1 shows a cross-sectional or side view of a spacer fabric 100 according to various aspects of the present disclosure. As shown, the first layer 110 of the spacer fabric 100 can include a first inner surface 310 and a first outer surface 312 opposite the first inner surface 310. The holes 116 extending through the first layer 110 are Figure 4 As described above, the first layer 110 can be considered to extend along an x- and y-plane. More specifically, the first inner surface 310 can lie along or define a first inner surface plane, as indicated by arrow 314, wherein the first inner surface plane 314 extends in the x- and y-directions. And the first outer surface 312 can lie along or define a first outer surface plane, as indicated by arrow 322, wherein the first outer surface plane 322 extends in the x- and y-directions. Similarly, the second layer 112 of the spacer textile 100 can include a second inner surface 316 and a second outer surface 318 opposite the second inner surface 316. Similar to the first inner surface 310, the second inner surface 316 can also lie along or define a second inner surface plane, as indicated by arrow 320, wherein the second inner surface plane 320 extends in the x- and y-directions, and wherein the second inner surface plane 320 is parallel to and offset from the first inner surface plane 314. Likewise, second outer surface 318 may extend along or define a second outer surface plane, as indicated by arrow 324 , where second outer surface plane 324 extends in the x-direction and the y-direction.

[0053] Continue to refer to Figure 4 , shows that the tie yarn 115 extends at least between the first inner surface 310 of the first layer 110 and the second inner surface 316 of the second layer 112, wherein the loop portion 326 of the tie yarn 115 extends into the first layer 110 and the loop portion 328 of the tie yarn 115 extends into the second layer 112 to interconnect the layers 110 and 112. To describe this in a different way, for Figure 4 In the illustrated spacer fabric 100 , the non-loop portion of the tie yarn 115 extends at least between the second inner surface plane 320 and the first inner surface plane 314 .

[0054] As described above, it is contemplated herein that the loop portions 326 and 328 of the tie yarns 115 can extend into the first layer 110 and the second layer 112, respectively. As such, a particular tie yarn, such as the tie yarn 117, can include a first length 321 measured in the direction of the first outer surface plane 322 between the second inner surface 316 (or second inner surface plane 320) and the loop portion 326 of the tie yarn 117. Due to variations in the weaving process used to produce the spacer fabric 100, it is contemplated that the tie yarns 115 may not all include the same length (e.g., the first length 321), but rather that the tie yarns 115 can include a first average length.

[0055] Now turn Figure 5 , shows a perspective view of the spacer fabric 100, wherein a portion of the first layer 110 has been removed at the second region 410 of the spacer fabric 100 and a variable length portion of the multifilament tie yarn 115 has been removed at the second region 410 (now labeled as tie yarns 510 and 512). The remaining region of the spacer fabric 100 other than the second region 410 may be referred to herein as the first region 412. To describe this differently, Figure 5 The spacer fabric 100 is depicted as including at least one first region 412 having a first layer 110, a second layer 112, and a third layer 114, and at least one second region 410 having the second layer 112, a portion of the third layer 114, but without the first layer 110. As will be explained in more depth below, an alkaline cellulolytic agent can be applied to the first layer 110 at the second region 410 using an exemplary application process. The alkaline cellulolytic agent is configured to remove / degrade the CD PET yarns in the first layer 110 at the second region 410. Similarly, the alkaline cellulolytic agent is configured to remove at least a portion of the length of the CD PET multifilament tie yarns 115 in the second region 410. The second layer 112 formed from non-CD PET yarns and / or polyamide-based and elastomeric yarn types is unaffected by the alkaline cellulolytic agent.

[0056] Against this background and with regard to Figure 5, the second region 410 is shown as having a generally rectangular shape, but it is contemplated that the second region 410 can include any shape, including shapes associated with branding (e.g., logos, images, etc.), geometric shapes, organic shapes, letters, numbers, etc. Furthermore, while only one second region 410 is shown, it is contemplated herein that the spacer textile 100 can include multiple second regions 410, wherein each second region 410 has the same shape or a different shape. When the spacer textile 100 includes multiple second regions 410, it is contemplated herein that the first region 412 can extend around or surround at least a portion of the second region 410. Any and all aspects and any variations thereof are considered within the aspects herein.

[0057] As mentioned, in the second region 410, the first layer 110 is removed or absent along with variable length portions of the tie yarn 115. More particularly, with respect to the tie yarns in the second region 410, tie yarns (e.g., tie yarn 510) located in areas adjacent to the apertures 116 in the first layer 110 prior to application of the alkaline cellulolytic agent can have a greater portion of their length removed than tie yarns (e.g., tie yarn 512) located in areas of the first layer 110 distal to the apertures 116 prior to application of the alkaline cellulolytic agent. In various aspects, this can be due to the greater permeability of the alkaline cellulolytic agent through the apertures 116 compared to the permeability of the alkaline cellulolytic agent in non-aperture areas of the first layer 110. Due to the greater permeability of the alkaline cellulolytic agent through the apertures 116, tie yarns located adjacent to the apertures 116 are degraded to a greater extent than tie yarns located further away from the apertures 116. Additionally, with respect to the tie yarns further away from the aperture, it is contemplated herein that when the alkaline fiber decomposer is applied to the first layer 110, the loop portions 326 of these tie yarns may be removed or degraded, but a remaining length of the tie yarn (e.g., the length between the first inner surface plane 314 and the second inner surface plane 320) may still exist.

[0058] For particular yarns located in the second region 410 (e.g., the tie yarn 510 and the tie yarn 512), when a portion of the length of the tie yarn 510 is removed, or when the loop portion of the tie yarn 512 is removed, it is contemplated that the integrity of the multifilament yarn strands forming the tie yarns 510 and 512 is disrupted so that the filaments within the tie yarns 510 and 512 are no longer tightly packed at least at their distal ends (i.e., the ends closest to the first inner surface plane 314) so ​​that the filaments are spread out relative to each other. As a result, the area surrounding the second region 410 (e.g., the first region 412) has the appearance of a spacer fabric, while the second region 410 has the appearance of a plush or pile-type fabric with yarns of variable length (e.g., the tie yarn 510 and the tie yarn 512). Functionally, Figure 5The illustrated spacer fabric 100 exhibits functional properties associated with spacer fabrics, such as compressibility, thermal insulation, temperature regulation, and increased air permeability, in the first region 412, as compared to a non-spacer fabric woven construction. Because the second region 410 includes a more open construction and lacks the first layer 110 and the variable length portion of tie yarns, the second region 410 generally exhibits higher air permeability than the first region 412 of the spacer fabric.

[0059] Figure 6 Describes the various aspects of this article Figure 5 1. A cross-sectional view of a spacer fabric 100 is shown. As shown, the first layer 110 is absent in the second region 410, and the tie yarns 510 and 512 in the second region 410 include at least two different lengths. To facilitate the following disclosure, the region in which the first layer 110 was present prior to removal is shown in phantom to provide an indication of the location of the aperture 116 and non-apertured areas of the removed first layer 110. The tie yarns 510 adjacent to the aperture 116 (i.e., the tie yarns 510 positioned along a reference line or plane extending through the aperture 116 in a direction toward the second layer 112) have a shorter length than the tie yarns 512 located further from the aperture 116 (i.e., the tie yarns 512 do not intersect the reference line or plane extending through the aperture 116 in a direction toward the second layer 112). For example, the tie yarn 510 may include a second length 414 measured in a direction extending toward the first outer surface plane 322 between the second inner surface 316 (or the second inner surface plane 320) and the distal end of the tie yarn 510. In various aspects, in the first region 412, the second length 414 of the tie yarn 510 is less than the first length 321 of the tie yarn 117. Furthermore, it is contemplated herein that the second length 414 of the tie yarn 510 is greater than zero (i.e., not all of the length of the tie yarn 510 is removed).

[0060] Continuing, the tie yarn 512 located in the removed non-aperture portion of the first layer 110 can include a third length 416 measured between the second interior surface 316 (or second interior surface plane 320) and the distal end of the tie yarn 512 in a direction extending toward the first exterior surface plane 322. In various aspects, in the first region 412, the third length 416 of the tie yarn 512 can be greater than the second length 414 of the tie yarn 510, but less than the first length 321 of the tie yarn 117. Due to variability in the processes used to remove a portion of the length of the tie yarns 510 and 512 in the first layer 110 and the second region 410, it is contemplated that the tie yarn 510 in the second region 410 may not all include the same length (e.g., the second length 414), and it is further contemplated herein that the tie yarn 512 in the second region 410 may not all include the same length (e.g., the third length 416).

[0061] Now turn Figure 7-9 According to aspects herein, a second configuration for a spacer fabric 700 is provided. Figure 7 , which shows a cross-sectional view of a spacer fabric 700 comprising a first layer 710, a second layer 712, and a third layer 714 interconnecting the first and second layers 710, 712. In various aspects, the first layer 710 comprises a continuous woven construction formed using CD PET yarn having a denier of about 18 to about 26 denier, about 20 to about 24 denier, or about 22 denier. The second layer 712 may also comprise a continuous woven construction formed using non-CD PET yarn. In some aspects, the non-CD PET yarn may comprise a polyamide yarn and an elastomeric yarn, and in some aspects, the elastomeric yarn may be wrapped with the polyamide yarn such that the yarn has a denier of about 40 to about 60 denier, about 45 to about 55 denier, or about 48 to about 50 denier. In various aspects, the third layer 714 can include one or more monofilament CD PET tie yarns 715 having a denier of from about 10 denier to about 20 denier, from about 13 denier to about 18 denier, or about 15 denier.

[0062] Similar to spacer fabric 100, first layer 710 of spacer fabric 700 has a first inner surface 716 defining a first inner surface plane 718 and a first outer surface 720 defining a first outer surface plane 722. Second layer 712 of spacer fabric 700 includes a second inner surface 724 defining a second inner surface plane 726 and a second outer surface 728 defining a second outer surface plane 730.

[0063] The monofilament tie yarn 715 forming the third layer 714 includes a loop portion 732 interlooped with the yarn forming the first layer 710 and a loop portion 734 interlooped with the yarn forming the second layer 712 to interconnect the two layers 710 and 712. The non-loop portion of the tie yarn 715 extends between the first inner surface 716 and the second inner surface 724. In various aspects, the tie yarn 715 can include at least a first length 736 measured between the second inner surface 724 (or the second inner surface plane 726) and the loop portion 732 of the tie yarn 715 in a direction extending toward the first outer surface 720 (or the first outer surface plane 722).

[0064] Figure 8 A perspective view of the spacer fabric 700 is depicted after an alkaline cellulolytic agent is applied to the second region 810 of the spacer fabric 700 to remove the first layer 710 in the second region 810 and the monofilament tie yarns 715 located in the second region 810. The remaining region of the spacer fabric 700 other than the second region 810 may be referred to herein as the first region 812. To describe this differently, Figure 8 The spacer fabric 700 is depicted as including at least one first region 812 having a first layer 710, a second layer 712, and a third layer 714, and at least one second region 810 having only the second layer 712 (without the first layer 714 and without the third layer 714). The use of fine denier yarns to weave the first layer 710 can allow for greater penetration of the alkaline cellulolytic agent into the third layer 714. This, combined with the use of fine denier monofilament CD PET tie yarns rather than multifilament tie yarns, promotes degradation and removal of the tie yarns 715 by the alkaline cellulolytic agent.

[0065] Although the second region 810 is shown as having a generally rectangular shape, it is contemplated that the second region 810 can include any shape, including shapes associated with branding (e.g., logos, images, etc.), geometric shapes, organic shapes, letters, numbers, etc. Furthermore, although only one second region 810 is shown, it is contemplated herein that the spacer textile 700 can include multiple second regions 810, wherein each second region 810 has the same shape or a different shape. When the spacer textile 700 includes multiple second regions 810, it is contemplated herein that the first region 812 can extend around or surround at least a portion of the second region 810. Any and all aspects and any variations thereof are considered within the aspects herein.

[0066] Continue to refer Figure 8, the area surrounding the second region 810 (e.g., the first region 812) has the appearance and functionality of a spacer fabric, while the second region 810 includes only the second layer 712. Functionally, the spacer fabric 700 exhibits functional properties associated with spacer fabrics, such as compressibility, thermal insulation, temperature regulation, and increased air permeability, in the first region 812, compared to a woven construction of a non-spacer fabric. Because the second region 810 includes a more open construction, eliminating the first layer 710 and the tie yarns 715, the second region 810 generally exhibits higher air permeability than the first region 812 of the spacer fabric 700.

[0067] Figure 9 Describes the various aspects of this article Figure 8 sectional and side views of a spacer fabric 700. As shown, in a second region 810, the first layer 710 is missing along with the tie yarn 715, such that the second region 810 includes only the second layer 712 without the first layer 710 and without the tie yarn 715. The first region 812 includes the first layer 710, the second layer 712, and the third layer 714, wherein the third layer includes the tie yarn 715 having a first length 736.

[0068] Now turn Figure 10-12 According to aspects of the present invention, a third configuration is provided. Figure 10 , which shows a cross-sectional view of a spacer fabric 700, wherein the spacer fabric includes a first layer 1010, a second layer 1012, and a third layer 1014 interconnecting the first and second layers 1010, 1012. In various aspects, the first layer 1010 comprises a continuous woven construction formed using CD PET yarn having a denier of about 18 to about 26 denier, about 20 to about 24 denier, or about 22 denier. The second layer 1012 may also comprise a continuous woven construction formed using non-CD PET yarn. In some aspects, the non-CD PET yarn may include polyamide yarn and elastomeric yarn, and in some aspects, the elastomeric yarn may be wrapped with polyamide yarn such that the yarn has a denier of about 40 to about 60 denier, about 45 to about 55 denier, or about 48 to about 50 denier. In various aspects, the third layer 1014 can include one or more multifilament CD PET tie yarns 1015 having a denier of about 15D to about 25D, about 17D to about 23D, about 19D to about 21D, or about 20D. Each tie yarn 1015 can include about 18 to about 30 filaments per tie yarn, about 20 to about 28 filaments per tie yarn, about 23 to about 25 filaments per tie yarn, or about 24 filaments per tie yarn.

[0069] Similar to spacer fabric 100 and spacer fabric 700, first layer 1010 of spacer fabric 1000 has a first inner surface 1016 defining a first inner surface plane 1018 and a first outer surface 1020 defining a first outer surface plane 1022. Second layer 1012 of spacer fabric 1000 includes a second inner surface 1024 defining a second inner surface plane 1026 and a second outer surface 1028 defining a second outer surface plane 1030.

[0070] The monofilament tie yarn 1015 forming the third layer 1014 includes a loop portion 1032 interlooped with the yarn forming the first layer 1010 and a loop portion 1034 interlooped with the yarn forming the second layer 1012 to interconnect the two layers 1010 and 1012. A non-loop portion of the tie yarn 1015 extends between the first inner surface 1016 and the second inner surface 1024, such that the tie yarn 1015 includes at least a first length 1036 measured between the second inner surface 1024 (or the second inner surface plane 1026) and the loop portion 1032 of the tie yarn 1015 in a direction extending toward the first outer surface 1020 (or the first outer surface plane 1022).

[0071] Figure 11 A perspective view of the spacer fabric 1000 is depicted after an alkaline cellulolytic agent has been applied to the second region 1110 of the spacer fabric 1000 to remove the first layer 710 in the second region 1110 and the loop portions 1032 of the multifilament tie yarns located in the second region 1110 (now labeled as tie yarns 1114). The remaining region of the spacer fabric 1000 other than the second region 1110 may be referred to herein as the first region 1112. To describe this differently, Figure 11 The spacer fabric 1000 is depicted as including at least one first region 1112 having a first layer 1010, a second layer 1012, and a third layer 1014, and at least one second region 1110 having the second layer 1012 and tie yarns 1114 without their loop portions 1032. Using fine denier yarns to weave the first layer 1010 can allow for greater penetration of the alkaline cellulolytic agent into the loop portions 1032 of the tie yarns 1114, thereby facilitating the removal or degradation of the loop portions 1032 in the tie yarns 1114 in the second region 1110.

[0072] Although the second region 1110 is shown as having a generally rectangular shape, it is contemplated that the second region 1110 can include any shape, including shapes associated with branding (e.g., logos, images, etc.), geometric shapes, organic shapes, letters, numbers, etc. Furthermore, although only one second region 1110 is shown, it is contemplated herein that the spacer textile 1000 can include multiple second regions 1110, wherein each second region 1110 has the same shape or a different shape. When the spacer textile 1000 includes multiple second regions 1110, it is contemplated herein that the first region 1112 can extend around or surround at least a portion of the second region 1110. Any and all aspects and any variations thereof are considered within the aspects herein.

[0073] Similar to spacer fabric 100, when the loop portion 1032 of the tie yarn 1015 is removed, the integrity of the multifilament yarn strands forming the tie yarn 1015 is disrupted, such that the filaments in the yarn strands are no longer tightly packed together at their distal ends (the ends closest to the first inner surface plane 1018), causing the filaments to spread out relative to each other. As a result, the area surrounding the second region 1110 (e.g., the first region 1112) has the appearance of a spacer fabric, while the second region 1110 has a plush or pile-type appearance with tie yarns 1114 of substantially uniform length. Functionally, spacer fabric 1000 exhibits functional properties associated with spacer fabrics, such as compressibility, thermal insulation, temperature regulation, and increased air permeability, in the first region 1112, compared to a woven construction of a non-spacer fabric. Because second region 1110 includes only second layer 1012 and tie yarns 1114 , second region 1110 may exhibit higher air permeability than first region 1112 of spacer textile 1000 .

[0074] Figure 12 Describes the various aspects of this article Figure 10-1110. A cross-sectional view of a spacer fabric 1000 is shown. As shown, the first layer 1010 is absent in the second region 1110, and the tie yarns 1114 in the second region 1110 lack their loop portions 1032. For example, the tie yarns 1114 can include a second length 1210 measured between the second inner surface 1024 (or second inner surface plane 1026) and the distal end of the tie yarns 1114 in a direction extending toward the first outer surface plane 1022. In various aspects, in the first region 1112, the second length 1210 of the tie yarns 1114 is less than the first length 1036 of the tie yarns 1114. Furthermore, it is contemplated herein that the second length 1210 of the tie yarns 1114 is greater than zero (i.e., not all of the tie yarns 1114 are removed). Due to variability in the process used to remove a portion of the length of the tie yarns 1114 in the first layer 1010 and the second region 1110, it is expected that the tie yarns 1114 in the second region 1110 may not all comprise the same length (e.g., the second length 1210), but instead may have an average length that is less than the first length 1036.

[0075] Aspects of the present invention contemplate incorporating the fabrics described herein (e.g., spacer fabrics 100, 700, and / or 1000) into garments. When incorporated into a garment, it is contemplated that the first region of the fabric (i.e., the region comprising the first, second, and third layers) may be located in areas of the garment where, for example, increased cushioning (e.g., pressure zones such as elbows, shoulders, knees, etc.) and / or increased insulation are desired. The second region of the fabric (i.e., the region where the first layer and a portion of the length of the tie yarn are absent or removed) will be positioned in areas of the garment where, when the garment is worn, the body experiences high heat and / or perspiration. Because these areas have a higher air permeability than, for example, the regions comprising the first, second, and third layers, air from the external environment may more easily enter the garment to help cool the wearer, and heat generated by the wearer may more easily escape the garment, further helping to keep the wearer cool.

[0076] According to the aspects of this article, Figure 13100. Garment 1300 is shown in the form of an upper body garment (e.g., a vest), but it is contemplated herein that garment 1300 may be in the form of a lower body garment, a full-body garment, or the like. Furthermore, while shown in the form of a vest, it is contemplated herein that garment 1300 may take other forms, such as a jacket, a pullover, a hoodie, a shirt, or the like. Any and all aspects and any variations thereof are considered within the aspects herein. In various aspects, garment 1300 may be formed entirely from one of the spacer fabrics described herein. Alternatively, one or more portions of garment 1300 may be formed from one or more spacer fabrics described herein, and other portions of garment 1300 may be formed from other types of fabrics (e.g., woven, non-woven, different weave configurations, etc.). To simplify the discussion, garment 1300 is described as being formed entirely from spacer fabric 1000. However, as previously discussed, it is contemplated herein that garment 1300 may also be formed from spacer fabric 100 or spacer fabric 700.

[0077] With respect to garment 1300, in various aspects, it is contemplated that first layer 1010 of spacer textile 1000 may comprise outer-facing surface 1310 of garment 1300. Second layer 1012 of spacer textile 1000 may form inner-facing surface 1312 of garment 1300. Figure 13 1300). In an alternative aspect (not shown), the first layer 1010 of the spacer textile 1000 can comprise the inner-facing surface of the garment 1300. In this aspect, the second layer 1012 would form the outer-facing surface of the garment 1300. Any and all aspects and any variations thereof are considered within the aspects herein.

[0078] like Figure 13 As shown, garment 1300 includes at least one area 1312 from which first layer 1010 and loop portion 1032 of tie yarn 1015 are removed. Although area 1312 is shown as a diamond shape, it is contemplated herein that the shape of area 1312 may include other shapes, such as a shape associated with a brand (e.g., a logo or image), other geometric shapes, organic shapes, etc. Area 1312 is located on garment 1300 at the torso portion of the front of garment 1300. In various aspects, when garment 1300 is worn, for example, based on a body's thermal or sweat profile, this area may correspond to a high heat or sweat area of ​​the wearer. The location of area 1312 on garment 1300 is illustrative only, and it is contemplated herein that garment 1300 may include other areas from which first layer 1010 and loop portion 1032 of tie yarn 1015 are removed (e.g., at the rear torso portion).

[0079] Now turn Figure 14, which depicts a flow chart of a method 1400 for forming a spacer fabric (such as spacer fabric 100, spacer fabric 700, or spacer fabric 1000) having one or more regions where a first layer of the spacer fabric is removed along with all of the tie yarn (e.g., spacer fabric 700) or a portion of the length of the tie yarn (e.g., spacer fabric 100 or spacer fabric 1000). At step 1410, an alkaline cellulolytic agent is applied to the first layer of the spacer fabric at one or more discrete regions, wherein the spacer fabric comprises a first layer, a second layer, and a third layer, and wherein the third layer is interwoven with the first and second layers. In some aspects, the first layer is formed from CD PET yarn, the second layer is formed from non-CD PET yarn (e.g., conventional PET yarn, polyamide yarn, elastomeric yarn, cotton yarn, etc.), and the third layer is made from monofilament CD PET yarn or multifilament CD PET yarn.

[0080] In some aspects, the alkaline fiber decomposing agent may comprise a base having a pH of at least 10. Some examples of suitable alkaline fiber decomposing agents include guanidine acid salts, phenols, alcohols, alkali metal hydroxides, and alkaline earth metal hydroxides. It is contemplated herein that the alkaline fiber decomposing agent may be dissolved in water to make it suitable for application. Suitable concentrations may be from about 15 wt % to about 30 wt %.

[0081] In various aspects, the alkaline fiber decomposing agent can be applied by a digital printing process, a screen printing process, an inkjet printing process, a roller printing process, or the like. Furthermore, parameters related to the alkaline fiber decomposing agent can be adjusted during the application process. For example, the amount of alkaline fiber decomposing agent applied can be adjusted by utilizing, for example, a two-pass or multi-pass printing process rather than a single-pass printing process. In some aspects, the amount of alkaline fiber decomposing agent applied can range from about 5 g / m2 to about 30 g / m2.

[0082] At step 1412, the fabric is heat treated to promote the removal and / or degradation of the CD PET yarn. In various aspects, the temperature can be from about 160°C to about 190°C, and the fabric can be subjected to the elevated temperature for about 10 minutes. At step 1414, the fabric is cleaned to remove any residual alkaline fiber decomposing agent and any decomposed / degraded yarn. One cleaning method is reduction cleaning using bisulfite, surfactants, and soda ash.

[0083] The method can further include incorporating a spacer fabric into the garment. In this aspect, the spacer fabric is incorporated into the garment such that the area where the first layer, along with a portion of the length of the tie yarn, is removed is positioned on the garment to correspond to areas of high heat or perspiration on the human body when the garment is worn.

[0084] The various aspects of the present disclosure have been described for illustrative and non-restrictive purposes. Alternative aspects that do not depart from the scope of the present invention will become apparent to those skilled in the art. Those skilled in the art may develop alternative means for achieving the aforementioned improvements without departing from the scope of the present invention.

[0085] It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are considered within the scope of the claims.Not all steps listed in all figures must be performed in the particular order described.

Claims

1. An integrated three-dimensional spacer fabric comprising A first area, the first area including: The first layer has a continuous woven construction; a second layer and a third layer, the third layer comprising a first monofilament tie yarn of a plurality of monofilament tie yarns interconnecting the first and second layers; and a second region comprising a second layer, wherein the plurality of monofilament tie yarns are absent in the second region, Wherein, the first layer includes a first yarn type, and the first yarn type includes cationic dyeable polyethylene terephthalate (CD PET).

2. The integrated three-dimensional spacer fabric according to claim 1, wherein: The first layer, the second layer, and the third layer are woven with each other in the first region.

3. The integrated three-dimensional spacer fabric according to claim 1, wherein: The first yarn type comprises a denier within a range of 20 denier to 24 denier.

4. The integrated three-dimensional spacer fabric according to claim 1, wherein: Each of the plurality of monofilament tie yarns includes a third yarn type comprising cationic dyeable polyethylene terephthalate (CD PET).

5. The integrated three-dimensional spacer fabric according to claim 1, wherein: Each of the plurality of monofilament tie yarns comprises 15 denier.

6. The integrated three-dimensional spacer fabric according to claim 1, wherein: The second layer is formed using one or more polyamide yarns and one or more elastomeric yarns.

7. The integrated three-dimensional spacer fabric according to claim 6, wherein: Each of the one or more elastomeric yarns is wrapped with a polyamide yarn.

8. The integrated three-dimensional spacer fabric according to claim 1, wherein: The first layer is absent at the second region.

9. A fabric comprising: orienting a first face in a first direction and a second face in a second direction opposite to the first direction; comprising a first region of a spacer fabric including a first knit layer, a second knit layer, and a third layer, the third layer including a monofilament tie yarn interconnecting the first and second knit layers; In a first region, the first woven layer includes a first side of the fabric oriented in the first direction; and a second region bounded by the first region, the first region forming a boundary around the second region, wherein within the boundary the monofilament tie yarn is absent from the fabric, and the second knit layer comprises a first side of the fabric and a second side of the fabric, The first woven layer is formed from a first yarn type comprising cationic dyeable polyethylene terephthalate (CD PET).

10. The fabric according to claim 9, wherein The first braided layer, the second braided layer, and the third layer are interwoven in the first region.

11. The fabric according to claim 9, wherein The first yarn type comprises a denier within a range of 20 denier to 24 denier.

12. The fabric according to claim 9, wherein The monofilament tie yarn comprises cationic dyeable polyethylene terephthalate (CD PET).

13. The fabric according to claim 9, wherein The monofilament tie yarn comprises a denier of 15.

14. The fabric according to claim 9, wherein The second braided layer comprises one or more polyamide yarns and one or more elastomeric yarns.

15. The fabric according to claim 14, wherein Each of the one or more elastomeric yarns is wrapped with a polyamide yarn.

16. The fabric according to claim 9, wherein The first braided layer is absent in the second region.

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