Knitted spacer fabric

Abstract

A knitted spacer fabric includes an upper fabric layer having a plurality of upper yarns and forming an upper surface of the knitted spacer fabric and a lower fabric layer having a plurality of lower yarns and forming a lower surface of the knitted spacer fabric. The knitted spacer fabric further comprises a plurality of zipper connecting yarns and a plurality of joining connecting yarns. The upper fabric layer includes a plurality of spaced apart parallel knitted upper columns, each upper column formed of at least two upper yarns knitted together, and the upper yarns from one column are not knitted together with the upper yarns of the adjacent column. At least a portion of the zipper connection yarn sews two adjacent upper columns together, and at least a portion of the engagement connection yarn sews one lower column and one upper column together.

Description

Technical Field

[0001] The present invention relates to knitted spacer fabrics and more particularly to knitted spacer fabrics for use as thermal insulation for garments. Background Art

[0002] Performance fabrics manufactured for thermal insulation clothing typically include fleece fabrics, i.e. fabrics with a napped or brushed surface for improving thermal insulation performance. The surface of such fabrics is typically formed of wool, which is raised by mechanical brushing, i.e. has a relatively high loft. However, it has been recognized that the brushing process often results in fiber breakage, which over time can loosen the broken fibers, potentially leading to microfiber contamination. For example, during washing, the loss of fibers can also lead to a degradation of thermal insulation performance. In addition, it is recognized that broken fibers released during the washing process can enter wastewater, causing pollution. It is desirable to have low fiber loss, low weight and high thermal insulation fabrics for outerwear and other clothing applications. Summary of the invention

[0003] The present invention relates to a knitted spacer fabric, comprising an upper fabric layer comprising a plurality of upper yarns, wherein the upper fabric layer forms an upper surface of the knitted spacer fabric. The knitted spacer fabric also comprises a lower fabric layer comprising a plurality of lower yarns, wherein the lower fabric layer forms a lower surface of the knitted spacer fabric. The knitted spacer fabric also comprises a plurality of zipper connecting yarns and a plurality of butt-jointing connecting yarns.

[0004] The upper fabric layer comprises a plurality of spaced apart parallel knitted upper columns, wherein each upper column is formed of at least two upper yarns knitted together, and the upper yarns from one column are not knitted together with the upper yarns of an adjacent column. The lower fabric layer comprises a plurality of spaced apart parallel knitted lower columns, wherein each lower column is formed of at least two lower yarns knitted together, and the lower yarns from one column are not knitted together with the lower yarns of an adjacent column. At least a portion of the zipper connecting yarn comprises a repeating pattern of at least one stitch in one upper column and at least one stitch in an adjacent upper column, and at least a portion of the linking connecting yarn comprises a repeating pattern of a plurality of stitches in one lower column and at least one stitch in one upper column. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Figure 1 is a simplified illustration of a cross-section of a knitted spacer fabric according to one embodiment of the present invention.

[0006] Figure 2 is a photograph of the upper surface of a knitted spacer fabric according to one embodiment of the present invention.

[0007] Figure 3 is an angled photograph of a knitted spacer fabric according to one embodiment of the present invention. DETAILED DESCRIPTION

[0008] Reference now Figure 1 The knitted spacer fabric 10 of the present invention has an upper surface 10a and a lower surface 10b, and comprises an upper fabric layer 100, a lower fabric layer 200, a plurality of zipper connecting yarns 300, and a plurality of connecting connecting yarns 400. The upper fabric layer 100 forms the upper surface 10a of the knitted spacer fabric 10, and the lower fabric layer 200 forms the lower surface 10b of the knitted spacer fabric 10.

[0009] The upper fabric layer 100 comprises a plurality of spaced apart parallel knitted upper rows 110, which are shown in FIG. Figure 1 . Each upper column 110 of the upper fabric layer 100 is formed by at least two upper yarns knitted together, and the upper yarns from one column are not knitted together with the upper yarns of the adjacent column. In one embodiment, each upper column is formed by at least two upper yarns knitted together and at least one zipper connecting yarn. This means that if the zipper connecting yarn 300 is missing or cut, the upper columns 110 will be completely separate independent knitted columns. At least a portion of the zipper connecting yarn includes a repeating pattern of at least one stitch in one upper column and at least one stitch in an adjacent upper column. Preferably, the repeating pattern of each zipper connecting yarn is stitched only on two adjacent upper columns 110. For example, the zipper connecting yarn starts with a stitch on the first upper column, then a stitch on the adjacent upper column, and then returns to a stitch on the first upper column again. A single zipper connecting yarn only travels between two adjacent upper columns and never travels to an additional third column. Such stitches create a zipper-like stitched appearance, which can be seen by Figure 2 See. Figure 2 is a photograph of an embodiment of a knitted spacer fabric viewed from the upper surface of the knitted spacer fabric. The lower fabric layer is not easily visible in this photograph because the lower row 210 is blocked from view by the upper row 110. In this example photograph, the zipper connecting yarn is white, and the upper appearance of the stitching between two adjacent upper rows 110 can be seen. In one embodiment, each upper row is formed by at least two upper yarns knitted together in a chain stitch. In another embodiment, the zipper yarn is sewn on three or more rows. For example, the zipper connecting yarn starts with stitching on the first upper row, then stitches on the adjacent upper row, then continues to stitch on the third row, then returns to the adjacent upper row again, and then stitches on the first upper row.

[0010] The stitching pattern of the zipper connecting yarn 300 helps control the spacing (and density per inch) of the upper columns. It is conceivable that tighter stitching of the zipper connecting yarn will produce a smaller "zipper"-like structure and upper columns that are closer together. Looser stitching of the zipper connecting yarn will produce a larger "zipper"-like structure and upper columns that are more separated. The distance between the upper columns can affect fabric stability, insulation value, and manufacturing cost. In a preferred embodiment, the average distance between the upper columns (measured from the centerline of one upper column to the centerline of the adjacent upper column) is about 0.25mm to 30mm, more preferably about 1mm to 10mm, and more preferably about 1mm to 4mm.

[0011] Refer to Figure 1 The knitted spacer fabric 10 further comprises a lower fabric layer 200 forming the lower surface 10b of the knitted spacer layer 10. The lower fabric layer comprises a plurality of spaced-apart parallel knitted lower layers 210, which are arranged at Figure 1 is shown as a rectangle in the simplified illustration of . Each lower row 210 is formed by at least two lower yarns knitted together, and the lower yarns from one lower row are not knitted together with the lower yarns of the adjacent lower row. Preferably, the lower rows are not directly connected to each other in any way, and if they were not connected to the upper row, the lower rows would be completely separate and not connected at all within the knitted spacer fabric 10. The zipper connecting yarns 300 are not sewn or knitted into the lower fabric layer 200. The upper and lower rows are parallel to each other (in this application, parallel is defined as being essentially knitted, and the rows, yarns and stitches can shift and move during knitting, sewing into a garment, wearing a garment and / or washing). The upper and lower rows are preferably parallel and also aligned, meaning that there is an upper row above each lower row. For example, this can be Figure 2 As seen in the figure, the lower fabric layer is basically invisible. Figure 3 (which is an image of the lower surface of a knitted spacer fabric) where the upper fabric layer is substantially invisible. For each lower column, there is a corresponding upper column aligned above and with the lower column.

[0012] The knitted spacer fabric 10 also includes a connecting yarn 400 (such as Figure 1). These joining yarns 400 connect the lower fabric layer to the upper fabric layer and connect the lower row to the upper row. Each joining yarn travels only between one lower row and one upper row (the upper row directly above and aligned with the lower row). The joining yarns do not connect the lower rows to each other or the upper rows to each other. Because each lower row is only connected to the upper row, the lower surface of the knitted spacer fabric has an almost fin-like appearance (the lower row forms a "fin"), and the lower row also has some movement because the connection is minimal. At least a portion of the joining yarns 400 includes a repeating pattern of multiple stitches in a single lower row and at least one stitch in an upper row. For example, the joining yarn starts with sewing multiple stitches on the first lower row, then sews stitches on the corresponding and aligned upper row, and then returns to sew stitches on the first lower row again. In one embodiment, each lower row is formed by at least two lower yarns knitted together in a chain stitch.

[0013] The stitching pattern of the joining yarn 400 helps control the spacing between the upper fabric layer 100 and the lower fabric layer 200 and the overall thickness of the knitted spacer fabric 10. It is conceivable that the tighter stitching of the joining yarn will produce a smaller yarn piece to connect the upper and lower rows and produce a thinner fabric 10. The looser stitching of the joining yarn will produce a larger yarn piece connecting the lower and upper rows and produce a thicker fabric 10. The distance between the two fabric layers 100, 200 can affect fabric stability, thermal insulation value and manufacturing costs. In a preferred embodiment, the average distance between the upper fabric layer and the lower fabric layer is about 1 to 75mm, more preferably about 2 to 20mm, more preferably about 2 to 10mm. Generally, the fabric preferably has a thickness of about 4mm to 12mm.

[0014] The knitted spacer fabric comprises at least a first yarn that contributes to forming a first fabric layer, a second yarn that contributes to forming a second layer, a zipper connecting yarn and a linking connecting yarn. Each of these yarns can be any suitable yarn. In the present application, "yarn" as used herein includes monofilament elongated bodies, multifilament elongated bodies, ribbons, strips, yarns, tapes, fibers, etc. The above-mentioned yarns can contain one type of yarn or any one or combination of multiple types of the above-mentioned yarns. The yarn can be in any suitable form, such as spun yarn, monofilament or multifilament, monocomponent, bicomponent or multicomponent, and has any suitable cross-sectional shape, such as circular, multi-lobed, square or rectangular (ribbon-shaped) and oval.

[0015] The yarn of the knitted spacer layer can be made of (but not limited to) cellulosic yarn (such as cotton, rayon, linen, jute, hemp, cellulose acetate and combinations, mixtures or blends thereof), polyester yarn (such as polyethylene terephthalate yarn, polytrimethylene terephthalate (PET) yarn, polytrimethylene terephthalate yarn), polybutylene terephthalate yarn and blends thereof), polyamide yarn (such as nylon 6 yarn, nylon 6,6 yarn, nylon 4,6 yarn and nylon 12 yarn), polyvinyl alcohol yarn, elastic polyester-polyurethane copolymer Polypropylene yarn, polyethylene yarn, polyvinyl acetate yarn, polylactic acid yarn, flame retardant meta-aramid Or para-aramid and combinations, mixtures or blends thereof.

[0016] In a preferred embodiment, the yarns of fabric 10 contain multifilament polyester yarns, as these have been shown to have good performance at low cost. In one embodiment, substantially all (defined as at least about 98% by weight) of all yarns in fabric 10 comprise multifilament polyester yarns. In one embodiment, the yarns making up the different parts of fabric 10 all have approximately the same thickness or denier. In other embodiments, there are differences in denier. In another embodiment, there may be more than one type of yarn (of different materials, constructions, and / or deniers) in the knit layer, or the yarns used may contain more than one type of fiber.

[0017] Preferably, the knitted spacer fabric has a clo value of at least about 0.5 as measured by test ASTM F1868. Clo (Rcf - fabric only) is a measure of the thermal insulation value of a fabric. In another embodiment, the knitted spacer fabric has a clo value (Rcf - fabric only) of at least about 0.3, more preferably at least about 0.7, as measured by test ASTM F1868. In another embodiment, the knitted spacer fabric 10 has an air permeability of at least about 150 CFM, more preferably about 175 CFM, more preferably about 200 CFM, more preferably about 225 CFM.

[0018] When fabric 10 is made into clothing (also referred to as clothes), in one embodiment, lower surface 10b will face away from the wearer, while upper surface 10a will face the wearer. In another embodiment, lower surface 10b will face the wearer, while upper surface 10a will face away from the wearer. Knitted spacer fabric 10 is a one-piece material formed together in a knitting machine, and fabric layers 100, 200 are not formed as separate knitted layers and then joined together in subsequent operations. Fabric 10 can be manufactured by any suitable knitting method, including warp knitting and weft knitting (or circular knitting). The clothing article can be any suitable article, including but not limited to shirts, jackets, pants, tights, leggings, hats, underwear and socks.

[0019] In another embodiment, a garment may use fabric 10 in addition to other fabrics. For example, a shirt may use fabric 10 of the present invention on the torso and another fabric in the sleeves. In addition, the fabric of the present invention may also be used as a lining.

[0020] In a preferred embodiment, the knitted spacer fabric 10 is connected (by quilting, sewing, etc.) to at least one other fabric. The fabric can be a woven or knitted fabric and can form the exterior of a garment or the interior of a garment. In another embodiment, the knitted spacer fabric 10 is sandwiched between two other fabrics. This allows the knitted spacer fabric 10 to act as an insulating layer without the worry of snagging, rubbing or other wear because it is protected on both sides by other fabrics (which can be woven or knitted). The knitted spacer fabric 10 can be laminated or bonded using an adhesive (or otherwise connected using sewing, grommets, etc.). The knitted spacer fabric 10 can also be coated with any suitable material, such as, but not limited to, foamed latex, antistatic materials, antifungal materials, stain removal chemicals, colorants, hydrophilic chemicals, or hydrophobic chemicals.

[0021] All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.

[0022] The terms "one" and "a kind of" and "the" and similar indicators used in the context of describing the subject matter of the present application (especially in the context of the appended claims) should be interpreted as covering the singular and plural, unless otherwise specified herein or clearly contradicted by the context. Unless otherwise specified, the terms "comprising", "having", "including" and "containing" should be interpreted as open terms (i.e., meaning "including but not limited to"), unless otherwise specified herein. The description of the numerical range herein is intended only to be used as a shorthand method for individually referring to each individual value falling within the range, and each individual value is incorporated into the specification as if it is individually described herein. All methods described herein can be performed in any suitable order, unless otherwise specified herein or clearly contradicted by the context. The use of any and all examples or exemplary language (e.g., "for example") provided herein is intended only to better illustrate the subject matter of the present application, without limiting the scope of the subject matter, unless otherwise stated. Any language in the specification should not be interpreted as indicating that any unclaimed element is essential to the practice of the subject matter described herein. The term "about" is used in the present application to represent an approximate number. Unless otherwise specified, the term "about" means within plus or minus 10% of the numerical value. For example, if a number of about 10 mm is given, this means 9-11 mm.

[0023] Preferred embodiments of the subject matter of the present application are described herein, including the best mode known to the inventor for implementing the claimed subject matter. After reading the foregoing description, variations of those preferred embodiments are apparent to those of ordinary skill in the art. The inventor expects that such variations will be appropriately adopted by those skilled in the art, and the inventor intends to practice the subject matter described herein in a manner different from that specifically described herein. Therefore, the present disclosure includes all modifications and equivalents of the subject matter described in the appended claims as permitted by applicable law. In addition, unless otherwise specified herein or clearly contradictory to the context, the present disclosure covers any combination of the above-mentioned elements in all possible variations thereof.

Claims

1. A knitted spacer fabric having an upper surface and a lower surface and comprising: an upper fabric layer comprising a plurality of upper yarns, wherein the upper fabric layer forms the upper surface of the knitted spacer fabric; a lower fabric layer comprising a plurality of lower yarns, wherein the lower fabric layer forms the lower surface of the knitted spacer fabric; a plurality of zipper connecting yarns; and, Multiple connecting yarns; wherein the upper fabric layer comprises a plurality of spaced-apart, parallel knitted upper columns, wherein each upper column is formed from at least two upper yarns knitted together, and wherein upper yarns from one column are not knitted together with upper yarns from an adjacent column; wherein the lower fabric layer comprises a plurality of spaced-apart parallel knitted lower columns, wherein each lower column is formed from at least two lower yarns knitted together, and wherein lower yarns from one column are not knitted together with lower yarns from an adjacent column; wherein at least a portion of the zipper connecting yarn comprises a repeating pattern of at least one stitch in one upper column and at least one stitch in an adjacent upper column; Wherein at least a portion of the engaging yarn comprises a repeating pattern of a plurality of stitches in a single lower row and at least one stitch in an upper row.

2. The knitted spacer fabric of claim 1, wherein each upper row is formed from at least two upper yarns knitted together in a chain stitch.

3. The knitted spacer fabric of claim 1, wherein each lower layer is formed from at least two lower yarns knitted together in a chain stitch.

4. The knitted spacer fabric of claim 1, wherein the upper row of knits is parallel to the lower row of knits.

5. The knitted spacer fabric of claim 1, wherein the lower rows of knitting are aligned with the upper rows of knitting.

6. The knitted spacer fabric of claim 1, wherein each upper row is formed from at least two upper yarns knitted together and at least one zipper connecting yarn.

7. The knitted spacer fabric of claim 1, wherein each lower layer is not connected to an adjacent lower layer.

8. The knitted spacer fabric of claim 1, wherein the first pattern portion comprises a repeating pattern of a stitch in one upper column and a stitch in an adjacent upper column.

9. The knitted spacer fabric of claim 1, wherein at least one of the zipper connecting yarn and the butt connecting yarn is elastic.

10. The knitted spacer fabric of claim 1, wherein the knitted spacer fabric is joined to an additional fabric layer.

11. A garment comprising a knitted spacer fabric having an upper surface and a lower surface, wherein the knitted spacer fabric comprises: an upper fabric layer comprising a plurality of upper yarns, wherein the upper fabric layer forms the upper surface of the knitted spacer fabric; a lower fabric layer comprising a plurality of lower yarns, wherein the lower fabric layer forms the lower surface of the knitted spacer fabric; a plurality of zipper connecting yarns; and, Multiple connecting yarns; wherein the upper fabric layer comprises a plurality of spaced-apart, parallel knitted upper columns, wherein each upper column is formed from at least two upper yarns knitted together, and wherein upper yarns from one column are not knitted together with upper yarns from an adjacent column; wherein the lower fabric layer comprises a plurality of spaced-apart parallel knitted lower columns, wherein each lower column is formed from at least two lower yarns knitted together, and wherein lower yarns from one column are not knitted together with lower yarns from an adjacent column; wherein at least a portion of the zipper connecting yarn comprises a repeating pattern of at least one stitch in one upper column and at least one stitch in an adjacent upper column; Wherein at least a portion of the engaging yarn comprises a repeating pattern of a plurality of stitches in a single lower row and at least one stitch in an upper row.

12. The knitted spacer fabric of claim 11, wherein each upper row is formed from at least two upper yarns knitted together in a chain stitch.

13. The knitted spacer fabric of claim 11, wherein each lower layer is formed from at least two lower yarns knitted together in a chain stitch.

14. The knitted spacer fabric of claim 11, wherein the upper row of knits is parallel to the lower row of knits.

15. The knitted spacer fabric of claim 11, wherein the lower rows of knitting are aligned with the upper rows of knitting.

16. The knitted spacer fabric of claim 11, wherein each lower row is not connected to an adjacent lower row.

17. The knitted spacer fabric of claim 11, wherein the first pattern portion comprises a repeating pattern of a stitch in one upper column and a stitch in an adjacent upper column.

18. The garment of claim 11, wherein the garment comprises an additional fabric layer.

19. The garment of claim 18, wherein the knitted spacer fabric is attached to the additional fabric layer.

20. The garment of claim 11, wherein the garment comprises two additional fabric layers and the knitted spacer fabric is located between the additional fabric layers.

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