Fabric wicking moisture and concealing sweat

Abstract

Aspects herein are directed to a moisture and sweat wicking knitted spacer fabric (100) and garments (700, 800) formed from the fabric that include a first knitted layer (110) formed from yarns that have been treated with a durable waterproof (DWR) finish prior to forming the first knitted layer (110); and a second knit layer (112) formed from yarns that have been treated with a wicking moisture finishing agent prior to forming the second knit layer (112). The first knit layer (110) and the second knit layer (112) are interconnected by tie threads (114). When the fabric (100) is formed into a garment (700, 800), the second knit layer (112) is configured to be positioned adjacent a skin surface (610) of a wearer and the first knit layer (110) forms an outward facing surface of the garment.

Description

[0001] This application is a divisional application of the invention application with application number 202280040885.0, filing date April 27, 2022, and invention name “Fabric that absorbs moisture and hides sweat”. Technical Field

[0002] Aspects herein relate to a fabric that wicks moisture and hides perspiration, and articles of apparel made from the fabric. Background Art

[0003] Conventional clothing articles with wicking finishes typically transfer sweat from the wearer's body surface to the outwardly facing surface of the clothing article, where the sweat evaporates. The presence of sweat on the outwardly facing surface of the clothing article may cause unsightly issues.

[0004] Other conventional articles of clothing may be constructed of fabrics that include a hydrophobic surface positioned adjacent to a wearer's body surface. The hydrophobic surface may reduce the absorption of sweat from the wearer's skin surface. While this may reduce the appearance of sweat on the outwardly facing surface of the article of clothing, the reduction in sweat removed from the wearer's skin may cause discomfort to the wearer.

[0005] The formation of a fabric having a hydrophobic surface and / or a wicking surface can be accomplished by applying a finish to a finished fabric (e.g., a knitted or woven fabric). Although the finish penetrates the fabric surface, the finish often fails to completely cover the yarns forming the fabric. As a result, the effectiveness of the finish decreases relatively quickly over time, e.g., due to washing. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Examples of various aspects of the present invention are described in detail below with reference to the accompanying drawings, in which:

[0007] Figure 1 A cross-sectional view of an exemplary knitted spacer fabric is shown according to aspects herein;

[0008] Figure 2 According to various aspects of the present invention, it is shown that Figure 1 a first surface formed by a first knitted layer of a knitted spacer fabric;

[0009] Figure 3 According to various aspects of the present invention, it is shown that Figure 1 an opposing second surface formed by a second knitted layer of a knitted spacer fabric;

[0010] Figure 4 According to various aspects of the present invention, a schematic diagram of a knitted structure is shown, which is used to form Figure 1 a first knitted layer of a knitted spacer fabric;

[0011] Figure 5A According to various aspects of the present invention, a schematic diagram of a first exemplary knitted structure is shown, which is used to form a first exemplary knitted structure. Figure 1 a second knitted layer of a knitted spacer fabric;

[0012] Figure 5B A schematic diagram of a second exemplary knitted structure is shown according to various aspects of the present invention, the second exemplary knitted structure is used to form Figure 1 a second knitted layer of a knitted spacer fabric;

[0013] Figure 6 According to various aspects of this article, Figure 1 A schematic diagram of a knitted spacer fabric positioned adjacent to a skin surface of a wearer;

[0014] Figure 7 According to various aspects of the present invention, it is shown that Figure 1 An exemplary upper body garment formed of a knitted spacer fabric;

[0015] Figure 8 According to various aspects of the present invention, it is shown that Figure 1 An exemplary bottom garment formed from a knitted spacer fabric; and

[0016] Fig. 9 According to various aspects of the present invention, the manufacturing Figure 1 Flowchart of an exemplary method of knitting a spacer fabric. Summary of the invention

[0017] The subject matter of the present invention is specifically described herein to meet statutory requirements. However, this description is not intended to limit the scope of this disclosure. On the contrary, the inventors have contemplated that the claimed or disclosed subject matter may also be implemented in other ways, in conjunction with other existing or future technologies, including combinations of different steps or steps similar to the steps described in this document. In addition, although the terms "step" and / or "box" may be used herein to identify different elements of the method employed, these terms should not be interpreted as implying any particular order between the various steps or boxes, unless or in addition to the order of the individual steps or boxes being explicitly described.

[0018] Traditional clothing items formed by fabrics with wicking finishes typically transfer sweat from the wearer's body surface to the outward surface of the clothing item, where the sweat diffuses and evaporates. The presence of sweat on the outward surface of the clothing item may cause unsightly problems. Other traditional clothing items may be composed of a fabric that includes a hydrophobic surface positioned adjacent to the wearer's body surface. The hydrophobic surface can reduce the absorption of sweat from the wearer's skin surface. Although this can reduce the appearance of sweat on the outward surface of the clothing item, the reduction of sweat removed from the wearer's skin may make the wearer feel uncomfortable. The formation of fabrics with hydrophobic surfaces and / or wicking surfaces can be completed by, for example, applying the finish to a finished fabric (e.g., a knitted or woven fabric) in a padding machine. Although the finish penetrates the fabric surface, the finish often fails to completely cover the yarns that form the fabric. As a result, for example, the effectiveness of the finish decreases relatively quickly over time due to washing.

[0019] Aspects of the present invention relate to a moisture wicking and sweat hiding fabric, and garments formed from the fabric that are lightweight, low-profile, breathable, and have stretch and recovery properties that make them ideal for athletic wear. The moisture wicking properties of the fabric help remove sweat from the surface of the wearer's skin, thereby improving the comfort of the wearer, and the sweat hiding properties of the fabric help prevent sweat from appearing on the outwardly facing surface of a garment formed from the fabric, thereby promoting a sleek and clean aesthetic.

[0020] In an exemplary aspect, the fabric is a knitted spacer fabric comprising a first knit layer formed of yarn that has been treated with a durable water repellent (DWR) finish prior to forming the first knit layer; and a second knit layer formed of yarn that has been treated with a wicking finish prior to forming the second knit layer. In an exemplary aspect, a tie yarn comprising an elastic yarn interconnects the first knit layer and the second knit layer, the elastic yarn comprising a bare elastic yarn. When the fabric is formed into a garment, the second knit layer is configured to be positioned adjacent to a skin surface of a wearer, and the first knit layer forms an outwardly facing surface of the garment.

[0021] The use of tie yarns satisfies several functions. For example, when the knitted construction of the first knit layer and the second knit layer are combined, the tie yarn helps to separate or space the first knit layer and the second knit layer, which creates a conventional open construction that promotes breathability and permeability. Separating or spacing the first knit layer and the second knit layer by the use of tie yarns can also prevent contamination of the finish between the layers and help isolate specific finishes (e.g., wicking or DWR) to one surface of the fabric. This is in contrast to, for example, a single knitted construction, in which the chances of different finishes applied to the fabric interacting with each other increase due to the side-by-side positioning of the yarns and the interwoven nature of the knitted construction, which negates the specific properties of the finish. This is also in contrast to, for example, a double knitted construction. In a double knitted construction, although the technical front and technical back can have different finishes, the finish may be transferred between the front and back due to the transfer of the yarn between the two surfaces during the knitting process. For example, if the technical face is formed from yarn treated with a DWR finish and the technical back is formed from yarn treated with a wicking finish, then when the yarn is transferred from the technical face to the technical back, the DWR finish will also be transferred to the technical back, and vice versa.

[0022] The use of bare (i.e., uncovered) elastic yarn as the tie yarn further helps to isolate the finish to their respective surfaces as opposed to other types of yarns such as cotton, nylon, monofilament, etc. This is because, in general, bare elastic yarns are not good moisture transporters, and by extension, are not good finish transporters. For example, with respect to spandex, spandex has a relatively low moisture regain (about 1.3%) compared to other fibers / filaments such as cotton (about 7%) and nylon (about 4.5%), which makes spandex less likely to absorb a particular finish and transport the finish between the knit layers. Similarly, spandex fibers / filaments typically have a smooth outer surface that has fewer channels or surface areas for transporting the finish between the two knit layers by capillary action. The stretch and recovery properties of the elastic yarn help to tension the first and second knit layers toward each other to create a low-profile aesthetic suitable for athletic wear. In contrast, typical knitted spacer fabrics that do not include elastic tie yarns are generally too bulky to be suitable for athletic wear, such as form-fitting leggings or tops.

[0023] When wearing a garment formed by the fabric described herein, the sweat generated by the wearer is absorbed by the second knitted layer due to, for example, the wicking moisture finish covering the yarn forming the second knitted layer. Due to capillary action, the sweat diffuses through the entire second knitted layer and then evaporates due to the open structure of the knitted spacer fabric. The bare stretch yarn minimizes the transfer of sweat to the first knitted layer. Any sweat transferred to the first knitted layer is repelled by the DWR finish, which covers the yarn forming the first knitted layer, and therefore the sweat will not show up on the outward surface of the garment. Therefore, the fabric described herein achieves a dual purpose, wicking moisture to remove sweat from the wearer's skin, improving the wearer's comfort and hiding any sweat absorbed by the fabric.

[0024] Aspects of the present invention contemplate applying a DWR and a wicking finish to the yarn before forming the fabric. For example, the DWR finish and the wicking finish can be applied to the yarn after the yarn dyeing step and before knitting the yarn to form a knitted spacer fabric. In one example, the yarn can be treated in a water bath containing a suitable finish so that the finish is evenly applied to all surfaces of the yarn (referred to herein as a "dyeing process"). In particular, with respect to the DWR finish, it has been found that applying the finish after dyeing the yarn creates a more durable finish compared to applying the DWR finish before dyeing the yarn. In contrast, applying the finish to a knitted fabric by a padding process generally deposits the finish on the surface of the yarn exposed to the pad, but the finish may not be evenly applied to the surface of all yarns, making the finish less durable. For example, the finish can only be applied to about 50% to 60% of the surface area of ​​a single yarn. The above-mentioned application method creates a fabric with a durable, long-lasting finish that can withstand repeated washings (e.g., up to at least 100 washes).

[0025] As used herein, the term "article of clothing", "garment" or "sportswear article or garment" refers to an article of clothing configured to be worn by a wearer. In an exemplary aspect, the article of clothing may be worn while the wearer is engaging in a physical activity. The article of clothing may be in the form of a lower body article of clothing, which may be form-fitting in certain aspects, such as leggings, tights, capri pants, shorts, etc.; an upper body article of clothing, which may be form-fitting in certain aspects, such as a shirt or a pullover; a support garment, such as a sports bra or a sports tank, etc. When referring to an article of clothing, the term "outward surface" refers to the surface that faces away from the wearer's body and toward the external environment. When referring to an article of clothing, the term "inward surface" refers to the surface that faces inward or toward the wearer's body. The term "outward-most surface" refers to the surface that is positioned farthest from the wearer's body relative to other layers or components of the article of clothing, and the term "inward-most surface" refers to the surface that is located closest to the wearer's body relative to other layers or components of the article of clothing.

[0026] The term "knitted spacer fabric" as used herein means a knitted spacer fabric including warp knitting and weft knitting, as known in the fabric art. Generally speaking, the spacer fabric is formed by interconnecting a first and a second knit layer of the fabric using at least one tie yarn. More specifically, each of the first and second layers can be knitted separately, and one or more tie yarns are used to connect the first and second knit layers. For example, the tie yarn can have a "loop" portion that extends into each of the first and second knit layers, wherein the loop portion interloops with the yarns in the first and second knit layers to connect the two layers.

[0027] Because each of the first knitted layer and the second knitted layer is knitted separately, each of the first knitted layer and the second knitted layer can be knitted using different yarn types and / or different knitting structures, even though the same yarn type and the same knitting structure can be used in each of the first knitted layer and the second knitted layer. Within a given knitted layer, a particular yarn can extend through at least a portion of the knitted layer. In order to distinguish between a knitted spacer fabric and a double knitted fabric, in a double knitted fabric, there is a transfer of yarn from the face layer to the back layer, and vice versa. In a knitted spacer fabric, there is no transfer of yarn from the first knitted layer to the second knitted layer. In other words, the yarn forming the first knitted layer and the yarn forming the second knitted layer are separated and different, and the first and second knitted layers are connected only by the tie yarn.

[0028] When describing, for example, yarn, the term "polyester fiber" means yarn having filaments and / or fibers formed from terephthalate polymers, and the term includes, for example, polyethylene terephthalate (PET), poly-1,4-cyclohexanedimethylene terephthalate (PCDT), polybutylene terephthalate (PCT), and polytrimethylene terephthalate (PTT). When describing yarn, the term "elasticity" as used herein means the ability of a strained or stretched yarn (e.g., stretched to about 400% of the original length of the yarn) to substantially recover the original length of the yarn (e.g., within about 10% or more of the original length of the yarn) within about 60 seconds or less after the stress is removed. Inelastic yarns may exhibit a certain degree of mechanical stretch, but will not substantially recover the original length of the yarn (e.g., within about 10% or more of the original length of the yarn) within 60 seconds after the stress is removed. Examples of elastic yarn types include, for example, spandex (also known as elastane), rubber, TPU polymer yarns, Etc. The term "bare elastic yarn" used herein means an elastic yarn that is not covered or wrapped by another yarn (eg, polyester fiber yarn).

[0029] As used herein, the term DWR finish is meant to refer to any chemical that, when applied or incorporated into a fabric, helps a fabric resist wetting. Exemplary DWR finishes include fluorocarbons, wax emulsions, metal soaps, surfactants, and the like. As used herein, the term "wicking finish" is meant to include any chemical that increases the wicking of moisture into a fabric and the drying time of the fabric. In exemplary aspects, the wicking finish acts to change or alter the molecular structure on the surface of a fiber or yarn so that moisture is broken down into smaller particles that are more easily wicked. Exemplary wicking finishes include wait.

[0030] Various measurements related to knitted spacer fabrics can be provided herein. For example, the basis weight is measured using the ISO3801 test standard in grams per square meter (gsm). The denier of the fiber / filament can be measured using ASTM D1577-07. The diameter of the fiber can be calculated based on the denier of the fiber. The term "regenerated polyester fiber" includes chopped PET fibers from shredded items, waste, unsalable materials, etc. and re-extruded PET fibers (fibers re-extruded using recycled PET fragments). Unless otherwise stated, all measurements provided herein are measured at standard ambient temperature and pressure (25 degrees Celsius or 298.15K, and 1 bar), and the knitted spacer fabric is in a resting (unstretched) state. DETAILED DESCRIPTION

[0031] Figure 1An exemplary knitted spacer fabric 100 is depicted. The knitted spacer fabric 100 includes a first knit layer 110 extending in an x, y plane and a second knit layer 112 extending in the x, y plane, wherein the second knit layer 112 is parallel to and offset or spaced from the first knit layer by one or more tie yarns 114, which are knitted with the first knit layer 110 and the second knit layer 112. In an exemplary aspect, the tie yarn 114 may include a bare elastic yarn, such as a bare spandex yarn. For example, the tie yarn 114 may include a single filament of spandex or elastane having a denier from about 10D to about 45D, from about 15D to about 40D, or from about 20D to about 30D. As used herein, the term "about" means within ±10% of the indicated value. As described, the use of bare spandex tie yarn minimizes the transfer of moisture between the first knit layer 110 and the second knit layer 112 due at least to the low moisture regain of spandex and its smooth surface. In addition, the use of elastic tie yarn helps to tension the first knit layer 110 and the second knit layer 112 toward each other to minimize the thickness of the knitted spacer fabric 100. This creates a low-profile aesthetic that is suitable for form-fitting sportswear.

[0032] Although only one tie yarn 114 is depicted, it is contemplated herein that more than one tie yarn 114 may be used to interconnect the first knit layer 110 and the second knit layer 112. Portions of the tie yarn 114 are indicated by reference numerals 113 and 115 and are shown in phantom to indicate that they are generally concealed from view in those areas where the tie yarn 114 is shown interlaced with the yarns forming the first knit layer 110 and the second knit layer 112, respectively. Throughout this disclosure, when referring to the tie yarn, the term "loop" or "loop-like portion" used relates to the portion of the tie yarn that extends into and interlaced with the yarns in the first knit layer 110 and the second knit layer 112.

[0033] Figure 1 The illustration of the knitted spacer fabric 100 shown is illustrative only. For example, it is contemplated herein that the first knit layer 110 and the second knit layer 112 may be positioned closer to each other than shown. Likewise, the orientation of the tie yarn 114 may be different than shown. For example, the tie yarn 114 may be oriented at an angle less than 90 degrees, rather than being perpendicular to the x, y planes of the first knit layer 110 and the second knit layer 112 as shown. Any and all aspects and any variations thereof are considered to be within the scope of this document.

[0034] Figure 2A view of a first surface 210 of a knitted spacer textile 100 formed from a first knit layer 110 of the knitted spacer textile 100 is depicted, wherein the first knit layer 110 is formed from yarn that has been treated with a DWR finish. Portions of the interlaced knit stitches forming the first knit layer 110 are depicted on the first surface 210. When incorporated into a garment, the first surface 210 will form an outwardly facing surface of the garment, and in some aspects, an outermost surface of the garment. Figure 2 Tie yarn 114 and second knit layer 112 are further depicted in FIG.

[0035] Figure 3 A view of a second surface 310 of a knitted spacer fabric 100 formed from a second knit layer 112 of the knitted spacer fabric 100 is depicted, wherein the second surface 310 is opposite the first surface 210. The second knit layer 112 is formed from yarn that has been treated with a wicking finish. Portions of the interlaced knit stitches that form the second knit layer 112 are depicted on the second surface 310. When incorporated into a garment, the second surface 310 is positioned adjacent to the skin surface of the wearer and forms an inner-facing surface of the garment, and in some aspects, forms an innermost surface of the garment. Figure 3 The tie yarn 114 and the first knit layer 110 are further depicted in FIG.

[0036] Figure 4 A schematic diagram of a knitted construction for a first knitted layer 110 positioned on a knitting machine is depicted. The needles on the knitting machine are depicted as black circles. The first knitted layer 110 is formed by a first yarn 410 and a second yarn 412 that is in an aplated relationship with the first yarn 410. Each of the first yarn 410 and the second yarn 412 can be knitted into a plurality of knit courses 414 (one of which is shown), wherein each knit course 414 includes continuous interlaced knit stitches, such as knit stitch 416. It is also contemplated herein that the knit course 414 can include other or alternative stitch types using the first yarn 410 and the second yarn 412, such as a drop stitch, a floating stitch, a pleated stitch, etc.

[0037] In an exemplary aspect, the first yarn 410 is a recycled polyester yarn that has been previously treated with a DWR finish. In an exemplary aspect, the first yarn 410 may have a denier of from about 20D to about 60D, from about 30D to about 50D, or about 40D. The first yarn 410 may include from about 35 filaments to about 60 filaments, from about 40 filaments to about 55 filaments, or about 48 filaments. Selecting the number of deniers and filaments within these ranges contributes to the lightweight characteristics of the knitted spacer fabric 100, while still providing the desired opacity for elegance and durability. In an exemplary aspect, the second yarn 412 is an elastic yarn including a bare elastic yarn, such as spandex having a denier of from about 15D to about 40D, from about 25D to about 35D, or from about 20D to about 30D. The use of the elastic second yarn 412 creates a tight knit construction that can act as a barrier to moisture penetration, promote opacity, and can contribute to the overall stretch and recovery properties of the knitted spacer textile 100 .

[0038] Figure 5A A schematic diagram of a first exemplary knitting construction for a second knitted layer 112 positioned on a knitting machine is depicted. The needles on the knitting machine are depicted as black circles. The second knitted layer 112 is formed by a first yarn 510 and a second yarn 512 that is in a plated relationship with the first yarn 510. Each of the first yarn 510 and the second yarn 512 can be knitted into a plurality of knitting lanes 514 (one of which is shown), wherein each knitting lane 514 includes continuous interlaced knitting stitches, such as knitting stitches 516. It is also contemplated herein that the knitting lanes 514 may include other or alternative stitch types using the first yarn 510 and the second yarn 512, such as drop stitches, floating stitches, pleat stitches, etc. Figure 5B A second exemplary knit construction for the second knit layer is shown that includes only the first yarn 510 without the plated second yarn 512 .

[0039] In exemplary aspects, the first yarn 510 is a regenerated polyester fiber yarn previously processed with a wicking finish. In exemplary aspects, the first yarn 510 can have a denier from about 20D to about 60D, from about 30D to about 50D or about 40D. The first yarn 510 may include from about 60 filaments to about 80 filaments, about 65 filaments to about 75 filaments or about 72 filaments. Selecting a denier within this range helps the lightweight properties of knitted spacer fabric 100, while still providing required opacity for elegance and durability. Selecting the number of filaments within this range can provide a larger surface area for wicking moisture. In contrast, since the first knitting layer 110 is configured to repel moisture rather than wicking moisture, a larger number of filaments may not be needed in the first knitting layer 110. In an exemplary aspect, when used, the second yarn 512 is an elastic yarn including a bare elastic yarn, such as spandex having a denier from about 15D to about 40D, from about 25D to about 35D, or about 30D. The use of the elastic second yarn 512 creates a tight knit construction and can contribute to the overall stretch and recovery properties of the knitted spacer fabric 100.

[0040] In an exemplary aspect, the parameters associated with the first knitted layer 110, the second knitted layer 112, and the tie yarn 114 can be modified based on the intended end use of the knitted spacer fabric 100. The parameters can include the knitting gauge, the denier of the elastic yarn used, and the use of the elastic yarn for the second knitted layer 112. For example, when comparing the use of the knitted spacer fabric 100 in a lower body garment in the form of leggings or yoga pants and the use of an upper body garment, the lower body garment may be required to have a relatively high degree of stretch and recovery to accommodate and support the larger muscle groups in the lower body. In addition, a relatively high degree of opacity may be required in the lower body garment. In contrast, for the upper body garment, a lighter fabric weight and less stretch and recovery may be required to aid in donning and doffing and the comfort of the wearer.

[0041] In one exemplary aspect, to achieve the desired properties of a lower body garment: opacity and a relatively high degree of stretch and recovery, the knitted spacer fabric 100 may be formed as follows: Figure 4 The knitted construction shown is for the first knitted layer 110 and Figure 5AThe knitted construction shown is for the second knitted layer 112. The knitted spacer fabric 100 can be knitted on a 36 gauge knitting machine, which forms a tight knitted construction to help provide opacity. In an exemplary aspect, a higher denier elastic yarn can be used to enhance the stretch and recovery properties of the knitted spacer fabric 100 compared to the upper body garment. For example, for the first knitted layer 110, the second yarn 412 can have a denier from about 25D to about 35D or about 30D; for the second knitted layer 112, the second yarn 512 can have a denier from about 25D to about 35D or about 30D; for the tie yarn 114, the tie yarn 114 can have a denier from about 25D to about 35D or about 30D. The use of relatively high denier elastic yarns can also contribute to the tight knitted construction and result in opacity. The above parameters of the knitted spacer fabric 100 for lower body garments create a total fabric weight of from about 220 grams per square meter (gsm) to about 270gsm, from about 230gsm to about 260gsm or about 250gsm. Relatively heavy fabrics can also enhance the opacity of lower body garments. The material content of lower body garments can include, by weight, about 70% recycled polyester fiber and 30% elastic (elastic), about 75% recycled polyester fiber and 25% elastic fiber, or about 77% recycled polyester fiber and 23% elastic fiber, to achieve the required stretch and recovery characteristics of lower body garments.

[0042] In one exemplary aspect, to achieve the desired properties of an upper body garment, the knitted spacer fabric 100 may be used Figure 4 The knitting construction for the first knitting layer 110 and Figure 5B. The knitted construction for the second knitted layer 112 depicted in FIG. The knitted spacer fabric 100 can be knitted on a 34 gauge knitting machine, which forms a relatively tight knitted construction to help provide opacity. In exemplary aspects, a lower denier elastic yarn can be used compared to the knitted spacer fabric 100 for the lower body garment because a high degree of stretch and recovery may not be necessary (due to the smaller muscle groups in the upper body than the lower body garment). For example, for the first knitted layer 110, the second yarn 412 can have a denier of about 15D to about 25D or about 20D, and for the tie yarn 114, the tie yarn 114 can have a denier from about 15D to about 25D or about 20D; the second knitted layer 112 does not include an elastic yarn. The above parameters of the knitted spacer fabric 100 for the upper body garment create a total fabric weight of from about 120 grams per square meter (gsm) to about 160gsm, from about 130gsm to about 150gsm, or about 140gsm. For upper body garments, relatively lightweight fabrics may be desired for comfort. The material content of lower body garments may include, by weight, about 80% recycled polyester and 20% elastane, about 85% recycled polyester and 16% elastane, or about 88% recycled polyester and 12% elastane, reflecting the relatively reduced need for stretch and recovery in upper body garments.

[0043] Figure 6A schematic diagram of a knitted spacer fabric 100 positioned relative to a body surface 610 of a wearer is depicted. As shown, the second surface 310 of the second knit layer 112 is positioned directly adjacent to the main body surface 610 and may be in direct contact with the main body surface 610 in some aspects. The first knit layer 110 is spaced apart from the second knit layer 112 by the tie yarn 114 so that the first knit layer 110 is not in contact with the body surface 610 of the wearer. As indicated by reference numeral 612, when the body surface 610 of the wearer begins to sweat, the sweat 612 is absorbed by the second knit layer 112, which is at least partially based on the wicking finish covering the first yarn 510 forming the second knit layer 112. As indicated by arrows 614, the sweat 612 spreads laterally along the second knit layer 112, where it evaporates due to the open knit construction of the second knit layer 112 and the knitted spacer fabric 100 in general. By using the bare elastic tie yarn 114, the transport of sweat to the first knit layer 110 is minimized. As indicated by arrows 616, any sweat 612 transported to the first knit layer 110 is generally repelled, based at least in part on the DWR finish covering the first yarns 410 forming the first knit layer 110. This action minimizes the appearance of the sweat 612 on the first surface 210 of the knitted spacer textile 100. Thus, the knitted spacer textile 100 achieves the dual purpose of wicking sweat away from the wearer's skin while minimizing the appearance of sweat on the first surface 210 of the knitted spacer textile 100, where it subsequently evaporates, thereby maintaining elegance and providing a clean aesthetic.

[0044] Figure 7 An upper body garment 700 is shown that is formed in whole or in part from a knitted spacer fabric 100. In an exemplary aspect, the first knitted layer 110 is formed from a knitted spacer fabric 100. Figure 4 , and is positioned as facing outward or externally as shown. Thus, the first knitted layer 110 forms the outward surface of the upper garment 700. In an exemplary aspect, the second knitted layer 112 (not seen) is formed by Figure 5B , and facing inward to form the inward surface of the upper garment 700. The upper garment 700 is depicted as a form-fitting vest having a front torso portion 710, a rear torso portion 712, a neck opening 714, a waist opening 716, a first sleeve opening 718, and an opposing second sleeve opening 720. Although shown as a vest, it is contemplated herein that the upper garment 700 may include other configurations, such as a top with sleeves, a jacket, a support garment, a bra, a hoodie, a half-vest, etc.

[0045] As described above, the parameters of the knitted spacer textile 100 may be adjusted to achieve desired properties for the upper body garment 700, including a desired amount of stretch and recovery, a desired level of opacity, a desired weight, etc., while still providing moisture wicking and sweat hiding properties.

[0046] Figure 8 A lower body garment 800 is shown that is formed in whole or in part from a knitted spacer fabric 100. In an exemplary aspect, the first knitted layer 110 is formed from Figure 4 800 and is positioned to face outward or outwardly as shown. Thus, the first knitted layer 110 forms the outward surface of the lower body garment 800. In an exemplary aspect, the second knitted layer 112 (not seen) is formed by Figure 5A The knitted construction shown in FIG. 1 is formed and faces inward; the second knitted layer 112 forms the inward surface of the lower garment 800. The lower garment 800 is depicted as a form-fitting yoga pant having a front torso portion 810, a rear torso portion 812, a waist opening 814, a first leg portion 816 having a first leg opening 818, and a second leg portion 820 having a second leg opening 822. Although shown as yoga pants, it is contemplated herein that the lower garment 800 may include other configurations, such as three-quarter tights, half tights, shorts, singlets, unitards, etc.

[0047] As described above, the parameters of the knitted spacer textile 100 may be adjusted to achieve desired properties for the lower body garment 800, including a desired amount of stretch and recovery, a desired level of opacity, a desired weight, etc., while still providing moisture wicking and sweat hiding properties.

[0048] Fig. 9A flow chart of an exemplary method 900 of manufacturing a knitted spacer fabric, such as the knitted spacer fabric 100, is described. At step 910, a DWR finish is applied to a first plurality of yarns, such as the first yarn 410. In an exemplary aspect, the DWR finish is applied after the first plurality of yarns has been subjected to a dyeing process but before the first plurality of yarns are knitted to form the knitted spacer fabric. An exemplary method of applying the DWR finish is an immersion dyeing process, wherein the first plurality of yarns are passed through a water bath containing the DWR finish. In an exemplary aspect, the first plurality of yarns can be in a water bath at about 50 degrees Celsius for about 30 minutes to ensure adequate coverage of the DWR finish. In an exemplary aspect, the process can cover from about 80% to about 100%, from about 90% to about 100%, or about 100% of the surface area of ​​the yarn with the DWR finish. At step 912, after applying the DWR finish to the first plurality of yarns using the immersion dyeing process, the first plurality of yarns are knitted to form a first knit layer. In an exemplary aspect, an anti-snagging chemical finish can be applied to the first knit layer to reduce snagging.In an exemplary aspect, the first plurality of yarns can be plated with a second yarn, such as second yarn 412, wherein the second yarn can include a bare elastic yarn.

[0049] At step 914, a wicking finish is applied to a second plurality of yarns, such as first yarn 510. In an exemplary aspect, the wicking finish is applied after the second plurality of yarns undergoes a dyeing process and before the second plurality of yarns are knitted to form a knitted spacer fabric. Similar to the method of applying a DWR finish, an exemplary method of applying a wicking finish is an immersion dyeing process, wherein the second plurality of yarns passes through a water bath containing the wicking finish. In an exemplary aspect, the second plurality of yarns can be in a 50 degree Celsius water bath for about 30 minutes to ensure adequate coverage of the wicking finish. The process can cover the surface area of ​​the yarn from about 80% to about 100%, from about 90% to about 100%, about 100% with the wicking finish. At step 916, after applying the wicking finish to the second plurality of yarns using an immersion dyeing process, the second plurality of yarns are knitted to form a second knit layer. In an exemplary aspect, the second plurality of yarns can be plated with a second yarn, such as second yarn 512, wherein the second yarn can include a bare elastic yarn. In this regard, the second knitted layer can be used for lower body garments, where a higher degree of stretch and recovery may be required. In a second exemplary aspect, the second knitted layer may not include the second yarn. In this regard, the second knitted layer can be used for upper body garments, where a high degree of stretch and recovery may not be required.

[0050] At step 918, the first knit layer and the second knit layer are interconnected using a plurality of tie yarns, such as tie yarn 114, which may include bare elastic yarn. In an exemplary aspect, the tie yarn may not have a finish applied thereto.

[0051] The following clauses represent exemplary aspects of the concepts contemplated herein. Any of the following clauses may be combined in a variety of subordinate ways to be subordinate to one or more other clauses. In addition, any combination of subordinate clauses (clauses that are explicitly subordinate to the preceding clauses) may be combined while remaining within the scope of the various aspects contemplated herein. The following clauses are examples and are not restrictive clauses.

[0052] Item 1: A knitted spacer fabric comprising: a first knit layer formed from a first plurality of yarns, the first plurality of yarns having been treated with a durable water repellent (DWR) finish prior to forming the first knit layer; a second knit layer formed from a second plurality of yarns, the second plurality of yarns having been treated with a wicking finish prior to forming the second knit layer; and a plurality of tie yarns interconnecting the first knit layer and the second knit layer, the plurality of tie yarns comprising bare elastic yarn.

[0053] Clause 2: The knitted spacer fabric of Clause 1, wherein the first plurality of yarns comprises recycled polyethylene terephthalate (PET) yarns.

[0054] Clause 3: The knitted spacer fabric of any of Clauses 1-2, wherein the bare elastic yarn is plated with the first plurality of yarns.

[0055] Clause 4: The knitted spacer fabric of any of Clauses 1 to 3, wherein the second plurality of yarns comprises recycled polyethylene terephthalate (PET) yarns.

[0056] Clause 5: The knitted spacer fabric of any of Clauses 1 to 4, wherein the bare elastic yarn is plated with a second plurality of yarns.

[0057] Item 6: A garment comprising: a knitted spacer fabric forming one or more portions of the garment, the knitted spacer fabric comprising: a first knit layer formed from a first plurality of yarns, the first plurality of yarns having been treated with a durable water repellent (DWR) finish prior to forming the first knit layer, the first knit layer forming an outermost surface of the garment; a second knit layer formed from a second plurality of yarns, the second plurality of yarns having been treated with a wicking finish prior to forming the second knit layer, the second knit layer forming an innermost surface of the garment; and a plurality of tie yarns interconnecting the first knit layer and the second knit layer, the plurality of tie yarns comprising bare elastic yarn.

[0058] Clause 7: The garment of Clause 6, wherein the first plurality of yarns comprises recycled polyethylene terephthalate (PET) yarn.

[0059] Clause 8: The garment of any of Clauses 6-7, wherein the bare stretch yarn is plated with the first plurality of yarns.

[0060] Clause 9: The garment of any of Clauses 6 to 8, wherein the second plurality of yarns comprises recycled polyethylene terephthalate (PET) yarn.

[0061] Clause 10: The garment of any of Clauses 6 to 9, wherein the bare stretch yarn is plated with the second plurality of yarns.

[0062] Clause 11: A garment as claimed in any one of clauses 6 to 10, wherein the garment is a leggings garment.

[0063] Clause 12: A garment as claimed in any one of clauses 6 to 10, wherein the garment is an upper body garment.

[0064] Item 13: A method of making a knitted spacer fabric, comprising: applying a durable water repellent (DWR) finish to a first plurality of yarns; after applying the DWR finish to the first plurality of yarns, knitting the first plurality of yarns to form a first knit layer; applying a wicking finish to a second plurality of yarns; after applying the wicking finish to the second plurality of yarns, knitting the second plurality of yarns to form a second knit layer; and interconnecting the first knit layer and the second knit layer using a plurality of tie yarns, the plurality of tie yarns comprising a bare elastic yarn.

[0065] Clause 14: The method of making a knitted spacer fabric according to Clause 13, wherein the DWR finish is applied to the first plurality of yarns after the first plurality of yarns have been dyed.

[0066] Clause 15: A method of making a knitted spacer fabric according to any one of clauses 13 to 14, wherein the wicking finish is applied to the second plurality of yarns after the second plurality of yarns have been dyed.

[0067] Clause 16: A method of making a knitted spacer fabric according to any one of clauses 13 to 15, wherein the DWR finish and the wicking finish are applied by an exhaust dyeing process.

[0068] Clause 17: The method of making a knitted spacer fabric according to any one of clauses 13 to 16, wherein knitting the first plurality of yarns to form the first knit layer comprises plating the first plurality of yarns with a bare elastic yarn during the knitting process.

[0069] Clause 18: The method of making a knitted spacer fabric according to any one of clauses 13 to 17, wherein knitting the second plurality of yarns to form the second knit layer comprises plating the second plurality of yarns with a bare elastic yarn during the knitting process.

[0070] Clause 19: The method of making a knitted spacer fabric according to any one of clauses 13 to 18, wherein the first plurality of yarns and the second plurality of yarns each comprise recycled polyethylene terephthalate (PET) yarn.

[0071] Clause 20: A method of making a knitted spacer fabric according to any one of clauses 13 to 19, wherein the bare elastic yarn has no DWR finish or wicking finish applied thereto.

[0072] Item 21: An upper body garment comprising: a knitted spacer fabric, the knitted spacer fabric comprising a first knit layer formed from a first plurality of yarns, the first plurality of yarns having been treated with a durable water repellent (DWR) finish prior to the first knit layer being formed; a second knit layer formed from a second plurality of yarns, the second plurality of yarns having been treated with a wicking finish prior to the second knit layer being formed; and a plurality of tie yarns interconnecting the first knit layer and the second knit layer, wherein the first plurality of yarns and the second plurality of yarns comprise from about 80% to about 90% of the knitted spacer fabric, by weight.

[0073] Clause 22: The upper body garment of Clause 21, wherein each of the first plurality of yarns and the second plurality of yarns comprises recycled polyethylene terephthalate (PET) yarn.

[0074] Clause 23: The upper body garment of any of Clauses 21-22, wherein the plurality of tie yarns comprises bare elastic yarn.

[0075] Clause 24: The upper body garment of any of Clauses 21 to 23, wherein the bare stretch yarn is plated with the first plurality of yarns.

[0076] Clause 25: An upper body garment as described in any one of Clauses 21 to 24, wherein the second knitted layer does not include elastic yarn.

[0077] Clause 26: An upper body garment according to any one of Clauses 21 to 25, wherein the first knitted layer forms an outwardly facing surface of the upper body garment.

[0078] Clause 27: An upper body garment according to any one of Clauses 21 to 26, wherein the second knitted layer forms an inwardly facing surface of the upper body garment.

[0079] Clause 28: The upper body garment of any one of Clauses 21 to 27, wherein the knitted spacer fabric comprises, by weight, from about 10% to about 20% elastic yarn.

[0080] Clause 29: The upper body garment of any one of Clauses 21 to 28, wherein the knitted spacer textile has a weight of from about 130 grams per square meter (gsm) to about 150 gsm.

[0081] Item 30: A lower body garment comprising: a knitted spacer fabric, the knitted spacer fabric comprising a first knit layer formed from a first plurality of yarns, the first plurality of yarns having been treated with a durable water repellent (DWR) finish prior to formation of the first knit layer; a second knit layer formed from a second plurality of yarns, the second plurality of yarns having been treated with a wicking finish prior to formation of the second knit layer; and a plurality of tie yarns interconnecting the first knit layer and the second knit layer, wherein the first plurality of yarns and the second plurality of yarns comprise, by weight, 70% to about 80% of the knitted spacer fabric.

[0082] Item 31: The lower body garment of Item 30, wherein each of the first plurality of yarns and the second plurality of yarns comprises recycled polyethylene terephthalate (PET) yarn.

[0083] Clause 32: The lower body garment of any of Clauses 30-31, wherein the plurality of tie yarns comprises bare elastic yarn.

[0084] Clause 33: The lower body garment of any of Clauses 30 to 32, wherein the bare elastic yarn is plated with the first plurality of yarns.

[0085] Clause 34: The lower body garment of any of Clauses 30 to 33, wherein the bare elastic yarn is plated with a second plurality of yarns.

[0086] Clause 35: A lower body garment according to any one of Clauses 30 to 34, wherein the first knitted layer forms an outwardly facing surface of the lower body garment.

[0087] Clause 36: A lower body garment according to any one of clauses 30 to 35, wherein the second knitted layer forms an inwardly facing surface of the lower body garment.

[0088] Clause 37: The lower body garment of any of Clauses 30 to 36, wherein the knitted spacer fabric comprises, by weight, from about 20% to about 30% elastic yarn.

[0089] Clause 38: The lower body garment of any one of Clauses 30 to 37, wherein the knitted spacer fabric has a weight of from about 240 grams per square meter (gsm) to about 260 gsm.

[0090] Item 39: A knitted spacer fabric comprising: a first knit layer formed from a first plurality of yarns, the first plurality of yarns having been treated with a durable water repellent (DWR) finish prior to forming the first knit layer such that from about 80% to about 100% of the surface area of ​​the first plurality of yarns can be covered with the DWR finish; a second knit layer formed from a second plurality of yarns, the second plurality of yarns having been treated with a wicking finish prior to forming the second knit layer such that from about 80% to about 100% of the surface area of ​​the second plurality of yarns can be covered with the wicking finish; and a plurality of tie yarns interconnecting the first knit layer and the second knit layer.

[0091] Clause 40: The knitted spacer fabric of Clause 39, wherein the plurality of tie yarns comprises bare elastic yarn.

[0092] Clause 41: The knitted spacer fabric of any of Clauses 39 to 40, wherein the first plurality of yarns comprises recycled polyethylene terephthalate (PET) yarns.

[0093] Clause 42: The knitted spacer fabric of any of Clauses 39 to 41, wherein the bare elastic yarn is plated with the first plurality of yarns.

[0094] Clause 43: The knitted spacer fabric of any of Clauses 39 to 42, wherein the second plurality of yarns comprises recycled polyethylene terephthalate (PET) yarns.

[0095] Clause 44: The knitted spacer fabric of any of Clauses 39 to 43, wherein the bare elastic yarn is plated with a second plurality of yarns.

[0096] Aspects of the present disclosure have been described, which are intended to be illustrative rather than restrictive. It will become apparent to those skilled in the art that alternative aspects that do not depart from the scope thereof will be apparent. Those skilled in the art may develop alternative methods to achieve the above improvements without departing from the scope of the present disclosure.

[0097] It is understood that certain features and subcombinations are useful and may be used without reference to other features and subcombinations and are contemplated within the scope of the claims. Not all steps listed in the figures need to be performed in the exact order described.

Claims

1. An upper body garment, comprising: Knitted spacer fabrics, including: a first knit layer comprising a first plurality of yarns that have been treated with a durable water repellent (DWR) finish prior to being knitted into the first knit layer, wherein the first plurality of yarns comprises recycled polyester and is plated with an elastic yarn, and wherein from about 80% to about 100% of the surface area of ​​each yarn of the first plurality of yarns is covered with the DWR finish; a second knit layer comprising a second plurality of yarns that have been treated with a wicking finish prior to being knitted into the second knit layer, wherein the second plurality of yarns comprises recycled polyester and no plated elastic yarn, and wherein from about 80% to about 100% of the surface area of ​​each yarn in the second plurality of yarns is covered with the wicking finish; and A plurality of tie yarns interconnecting the first knit layer and the second knit layer, the plurality of tie yarns comprising bare elastic yarn.

2. The upper body garment of claim 1, wherein at least one of the recycled polyester of the first plurality of yarns and the recycled polyester of the second plurality of yarns comprises re-extruded polyethylene terephthalate (PET) fiber.

3. The upper body garment of claim 1, wherein at least one of the recycled polyester of the first plurality of yarns and the recycled polyester of the second plurality of yarns comprises chopped polyethylene terephthalate (PET) fibers.

4. A lower body garment, comprising: A knitted spacer fabric comprising one or more portions of the garment, the knitted spacer fabric comprising: a first knit layer comprising a first plurality of yarns that have been treated with a durable water repellent (DWR) finish prior to being knitted into the first knit layer, the first knit layer comprising an outermost surface of the garment, wherein the first plurality of yarns comprises recycled polyester, wherein the first plurality of yarns comprises a first filament count, and wherein from about 80% to about 100% of a surface area of ​​each yarn in the first plurality of yarns is covered with the DWR finish; a second knit layer comprising a second plurality of yarns that have been treated with a wicking finish prior to being knitted into the second knit layer, the second knit layer comprising an innermost surface of the garment, wherein the second plurality of yarns comprises recycled polyester, wherein the second plurality of yarns comprises a second number of filaments greater than the first number of filaments, and wherein from about 80% to about 100% of a surface area of ​​each yarn in the second plurality of yarns is covered with the wicking finish; and A plurality of tie yarns interconnecting the first knit layer and the second knit layer, the plurality of tie yarns comprising bare elastic yarn.

5. The lower body garment of claim 4, wherein at least one of the recycled polyester of the first plurality of yarns and the recycled polyester of the second plurality of yarns comprises re-extruded polyethylene terephthalate (PET) fiber.

6. The lower body garment of claim 5, wherein the bare stretch yarn is plated with the first plurality of yarns.

7. The lower body garment of claim 4, wherein at least one of the recycled polyester of the first plurality of yarns and the recycled polyester of the second plurality of yarns comprises chopped polyethylene terephthalate (PET) fibers.

8. The lower body garment of claim 7, wherein the bare stretch yarn is plated with the second plurality of yarns.

9. A method of making an upper body garment comprising a knitted spacer fabric, the method comprising: applying a durable water repellent (DWR) finish to a first plurality of yarns, the first plurality of yarns comprising recycled polyester; knitting the first plurality of yarns into a first knit layer after applying the DWR finish to the first plurality of yarns, the first plurality of yarns being plated with the elastic yarn, wherein from about 80% to about 100% of the surface area of ​​each yarn of the first plurality of yarns is covered with the DWR finish; applying a wicking finish to a second plurality of yarns, the second plurality of yarns comprising recycled polyester; knitting the second plurality of yarns into a second knit layer after applying the wicking finish to the second plurality of yarns, wherein the second plurality of yarns is free of plated elastic yarns, wherein from about 80% to about 100% of the surface area of ​​each yarn of the second plurality of yarns is covered with the wicking finish; and The first knit layer and the second knit layer are interconnected using a plurality of tie yarns, the plurality of tie yarns comprising bare elastic yarn.

10. The method of making an upper body garment according to claim 9, wherein the DWR finish is applied to the first plurality of yarns after the first plurality of yarns have been dyed.

11. The method of making an upper body garment according to claim 9, wherein the wicking finish is applied to the second plurality of yarns after the second plurality of yarns have been dyed.

12. The method of making an upper body garment according to claim 9, wherein the DWR finish and the wicking finish are applied by an exhaust process.

13. The method of manufacturing an upper body garment according to claim 9, wherein the first plurality of yarns and the second plurality of yarns each comprise at least one of re-extruded polyethylene terephthalate (PET) fibers and chopped polyethylene terephthalate (PET) fibers.

14. The method of making an upper body garment according to claim 9, wherein the bare elastic yarn has no DWR finish or wicking finish applied thereto.

15. The lower body garment of claim 4, wherein the second plurality of yarns comprises from about 60 to about 80 filaments, and wherein the first plurality of yarns comprises from about 35 to about 60 filaments.

16. The lower body garment according to claim 4, wherein: The knitted spacer fabric comprises a basis weight between about 220 gsm and about 270 gsm.

17. The lower body garment of claim 4, wherein the first plurality of yarns comprises a first denier from about 20D to about 60D, and wherein the second plurality of yarns comprises a second denier from about 20D to about 60D.

18. The lower body garment of claim 17, wherein the first denier is the same as the second denier.

19. The lower garment of claim 17, wherein the second denier is approximately 40D.

20. The method of claim 9, wherein the first plurality of yarns are dyed prior to applying the DWR finish, and wherein the second plurality of yarns are dyed prior to applying the wicking finish.

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