Spacer fabric

Abstract

A spacer textile is disclosed with a first layer comprising a moisture-wicking yam, a second layer comprising a moisture-absorbing yarn, a plurality of wicking threads formed of a multi- filament yarn interconnecting the first layer and the second layer, and a plurality of resilient threads interconnecting the first layer and the second layer. Also disclosed is a method of making a spacer textile. Spacer textiles according to the disclosure have uses in garments and in other applications.

Description

[0001] SPACER FABRIC

[0002] FIELD OF THE INVENTION

[0003] The present invention relates to spacer textiles, methods of making such spacer textiles and garments incorporating such spacer textiles.

[0004] BACKGROUND OF THE INVENTION

[0005] Spacer textiles typically comprise two separate, spaced apart fabrics layers connected by relatively resilient monofilaments extending between the two fabric layers. The monofilaments interconnecting the two fabric layers provide a three dimensional quality to the textile (since the fabric layers are spaced apart) and also provide a degree of compressibility and resilience perpendicular to the surface of the textile. Spacer textiles are currently used as replacements for conventional foam materials such as polyurethane. Further advantages of spacer textiles are that they offer enhanced air and moisture permeability compared to foams which makes spacer textiles more desirable than foam materials in shoes, protective and other garments and other items worn close the body.

[0006] WO-A-2006 / 100434 discloses a flexible spacer fabric, the fabric having a liquid permeable and breathable upper surface layer, a heat and liquid dissipating spacer layer, and a dimensionally stable lower surface layer. WO-A-2010 / 133877 discloses a knitted fabric comprising a first fabric layer, a second fabric layer and a plurality of pliable threads having a predetermined length, the respective ends of the pliable threads being stitched to the first and second layers thereby connecting the first and second layers. WO-A-2012 / 153131 discloses spacer textiles comprising a first and a second fabric layer with filaments of poly ether ether ketone (PEEK) connecting the layers. US-B2-11 591 726 discloses a spacer textile comprising a first layer, a second layer, and a plurality of tie yarns that interconnect the first layer and the second layer. The spacer textile further comprises one or more discrete areas from which the first layer is absent along with a portion of the length of the tie yarns in those areas. There is still a need, however, to provide improved moisture control using spacer fabrics, and especially to provide fabrics that enhance movement of moisture away from moist surfaces, for example, perspiration on skin.

[0007] It is an aim of the present invention to address such a need.

[0008] SUMMARY OF THE INVENTION

[0009] The present invention accordingly provides, in a first aspect, a spacer textile comprising, a first layer comprising a moisture-wicking yarn, a second layer comprising a moistureabsorbing yarn, a plurality of wicking threads formed of a multi-filament yarn interconnecting the first layer and the second layer, and a plurality of resilient, optionally mono-filament, threads interconnecting the first layer and the second layer.

[0010] The great and surprising advantage of this arrangement is that it provides essentially surface to surface moisture wicking spacer fabrics that may be used, for example, in apparel applications. The spacer textile, in use, may actively draw moisture (such as perspiration) away from the surface in which it is in contact, (for example skin or under garments) to improve the user’s thermophy si ologi cal comfort. Wicking may be greater in one direction than the other.

[0011] The plurality of resilient threads may resist compression (i.e. may be relatively stiff compared to the plurality of wicking threads formed of a multi-filament yam). Preferably, the plurality of resilient threads comprise a plurality of mono-filament resilient threads.

[0012] Generally, the yarns are provided from rolls and are of indefinite length. Thus, a plurality of wicking threads formed of a multi-filament yam interconnecting the first layer and the second layer may optionally be achieved by opposing ends of a portion of each wicking thread being stitched respectively to the first and second layers thereby connecting the first and second layers. Similarly, a plurality of resilient threads interconnecting the first layer and the second layer may optionally be achieved by opposing ends of a portion of each resilient thread being stitched respectively to the first and second layers thereby connecting the first and second layers.

[0013] The moisture wicking yam may comprise a yarn having at least a portion that is hydrophobic.

[0014] The wicking threads may comprise a yarn having at least a portion that is hydrophobic. Hydrophobic threads may have improved wicking properties.

[0015] The moisture wicking yam and / or the wicking threads may comprise a yarn that absorbs 15% by weight or less water.

[0016] The moisture wicking yam and / or the wicking threads may comprise a yarn having a wicking-enhancing cross section over at least a portion of the yarn. The wicking enhancing cross section may be such as to enhance capillary movement of moisture along the yarn, for example, by providing a cross section that is substantially heart shaped,, dog-bone shaped, or approximates or substantially comprises an n-foil cross section, wherein n is selected from one of 2, 3, 4, 5, 6, or 7. Thus, the n-foil cross section may be substantially, or approximate to, a lemniscate-like shape, a trefoil, a quatrefoil, a cinqfoil, a sexfoil or a septfoil cross section, for example.

[0017] The moisture wicking yam and / or the wicking threads may comprise polyester, polyamide, polyaramid and / or a mixture thereof.

[0018] The moisture-absorbing yam may comprise a cellulosic yarn. Optionally, the moistureabsorbing yarn may comprise 20 to 80% by weight of cellulosic yarn, optionally 25 to 70% by weight of cellulosic yam, optionally 25 to 60% by weight of cellulosic yarn, optionally 30 to 50% by weight of cellulosic yarn.

[0019] The second layer may further comprise multifilament polyester and / or multifilament polyamide yam.

[0020] The cellulosic yam may comprise cotton, optionally compact spun cotton.

[0021] The resilient threads may comprise monofilament polyester.

[0022] The textile thickness may be in the range 0.5 mm to 4 mm.

[0023] Preferably, the spacer textile is warp knitted.

[0024] The spacer textile may comprise fire resistant yam / fabrics (e.g. aramid, for example metaaramid and / or para-aramid) if desired.

[0025] The present invention provides, in a second aspect, a method of making a spacer textile, the method comprising, a. forming a first layer comprising a moisture-wicking yarn, b. forming a second layer comprising a moisture-absorbing yam, c. connecting the first layer and the second layer with a plurality of wicking threads formed of a multi-filament yarn interconnecting the first layer and the second layer, and d. connecting the first layer and the second layer with a plurality of resilient threads interconnecting the first layer and the second layer.

[0026] The method is preferably a warp knitting method.

[0027] The method may further comprise one or more steps selected from stenter heatset, beam scour, and stenter dry.

[0028] Depending on the intended use, other modifications and optional features of spacer textiles according to the invention may include: a) the spacer textile may comprise inherently anti-bacterial yam (e.g. a yarn that contains an anti-bacterial additive, for example, comprising silver particles / nanoparticles) within the polymer / fibre thereby providing anti-bacterial and / or anti-microbial properties; anti-bacterial yarns may be based on polyester, nylon, viscose, cotton, polyethylene; b) the spacer textile may comprise a yam that has undergone anti-bacterial finishing treatments: e.g. anti-bacterial or anti-microbial treatments that may be applied in the textile finishing process; c) the spacer textile may have undergone softener treatment; softener treatments that may be applied to the textile during the finishing stage to improve the overall softness of the fabric: the level and type of softener treatment may be tailored to suit the intended use and requirement; d) the spacer textile may comprise a yam that is inherently fire resistant (FR), e.g. yarn that contains fire resistant additives, or a treatment which provides fire resistant properties; possible FR yarns / fibres may include polyester, nylon, cotton, viscose, aramid (e.g. metaaramid and / or para-aramid); e) the spacer textile may comprise a recycled or regenerated yarns and / or fibre; including synthetic polymers such as polyester, nylon and polyethylene, and organic natural fibres such as organic cottons and viscose; f) the spacer textile may have various thicknesses depending on intended use, for example, fabric thickness may range from 1 mm to 12 mm; g) the spacer textile may comprise layers with various surface construction and / or knitting patterns to meet aesthetic or functional requirements. For example, surface design may include constructions ranging from a solid jersey -type surface construction, to open meshtype construction.

[0029] Spacer textiles according to the first aspect find uses in many areas including apparel / garments.

[0030] Thus, in a third aspect, the present invention provides a garment comprising a spacer textile according to the first aspect.

[0031] Preferably, the spacer textile is arranged in the garment so the first layer, when the garment is worn, is proximal the skin of the wearer.

[0032] Applications of fabrics according to the invention may also include: a) sanitary protection products (such as tampons or sanitary pads) for use in menstrual sanitary products owing to the high-absorbency and high wicking of the spacer textiles according to the invention; thus in an aspect there is provided a sanitary protection product comprising a spacer textile according to the first aspect; b) healthcare, for use as a comfort layer in bandages and dressings with the advantages of the moisture wicking performance of the spacer textiles; thus in an aspect there is provided a dressing comprising a spacer textile according to the first aspect; c) military, for use in e.g. military garments to improve the thermophysiological comfort for the user, as well as providing a comfort layer in, for example, ballistic vests, helmet linings, jacket linings, backpack support and other garments; such spacer textiles may also include fire resistant additives or yams; thus in an aspect there is provided a military garment and / or a comfort layer comprising a spacer textile according to the first aspect; d) nursery, for use as a comfort layer with the addition of the moisture wicking performance in nappies / diapers, children’s clothing, bedding and other nursery and children’s fabrics; thus in an aspect there is provided a nappy / diaper comprising a spacer textile according to the first aspect; e) personal protective equipment (PPE), for use as a comfort layer with the addition of the moisture wicking performance, in, for example, protective clothing, firefighter jackets to provide moisture management characteristics to improve the thermophysiological comfort for the wearer. Such spacer textiles according to the invention may also include fire resistant additives or yarns. Thus, in an aspect there is provided personal protective equipment comprising a spacer textile according to the first aspect;

[0033] The various features of aspects of the disclosure as described herein may be used in combination with any other feature in the same or other aspect of the disclosure, if needed with appropriate modification, as would be understood by the person skilled in the art.

[0034] Furthermore, although all aspects of the invention or disclosure preferably “comprise” the features described in relation to that aspect, it is specifically envisaged that they may “consist” or “consist essentially” of those features outlined in the claims.

[0035] In this specification, the words “textile” and “fabric” are used interchangeably unless the context otherwise requires.

[0036] BRIEF DESCRIPTION OF THE FIGURES

[0037] The invention will now be described with reference to the accompanying Figures, in which:

[0038] Figure 1 depicts a spacer textile of Comparative Example A made from 100% polyester on both faces and standard monofilament filler yarns, showing (a) a face to which coloured dye was applied and (b) the other face.

[0039] Figure 2 depicts the (a), (b) polyester and (c ), (d) cellulosic faces of the spacer textile of Example 2, (a) with dye applied to the polyester face and showing (b) the cellulosic face; and (c ) with dye applied to the cellulosic face and (d) the polyester face.

[0040] Figure 3 depicts a simulated top-down view of the design of spacer textile of Example 2 from the polyester face i.e. the technical front of the fabric.

[0041] Figure 4 depicts a simulated top-down view of the design of spacer textile of Example 2 from the cellulosic face i.e. the technical back of the fabric.

[0042] Figure 5 depicts a magnified and simulated top-down view of the design of the spacer textile of Example 2 from the polyester face (i.e. the technical front of the fabric) with the cellulosic face omitted for clarity.

[0043] Figure 6 depicts a magnified and simulated top-down view of the design of the spacer textile of Example 2 from the cellulosic face (i.e. the technical back of the fabric) with the polyester face omitted for clarity. Figure 7 depicts a cross-sectional simulated view of the design of the spacer textile of Example 2.

[0044] Figure 8 depicts an enhanced simulated view of the design of the spacer textile of Example 2.

[0045] Figure 9 is a photograph of spacer textile of Example 2 indicating the polycotton face 20 and polyester face 10.

[0046] DETAILED DESCRIPTION OF THE INVENTION

[0047] Spacer textiles according to the disclosure are designed to be surface to surface moisture wicking spacer fabrics that may be used in apparel applications. The great advantage of this spacer textile is that it actively draws moisture away from the surfaces, such as perspiration on skin to improve the user’s thermophy si ological comfort. The spacer textile may be a knitted fabric that controls the movement of moisture to provide the effect by using a combination of (high-wicking, hydrophobic) polyester yams and (high-absorbing, hydrophilic) cellulosic yarns.

[0048] The disclosure will be further illustrated by the following Examples which describe spacer textiles and methods according to the invention.

[0049] Examples

[0050] Spacer textiles were produced according to the procedure detailed below.

[0051] Technical Front Face: the technical front face was formed from 100% high-wicking polyester multifilament yam with high-wicking cross-sectional profile aiding in the movement of moisture through capillary action. Essentially, high-wick polyester yams it has been discovered move moisture better compared to conventional (non-high wicking profile) polyester yarns. In use the technical front face is preferably located against the wearer’s skin.

[0052] 3D Filler: connecting the front and back face are threads of monofilament polyester yarn to provide compression resistance. Additionally, connecting the front and back face are threads of high-wicking multifilament polyester yarn to provide moisture transfer between the front and back face through capillary action. Technical Back Face: the technical back face is formed of a cellulosic / polyester blended yarn that may have varying blend levels of 80>20% cotton. The yarns used in Example 1 and 2 have 40% compact spun cotton, 60% conventional (non-high wicking) polyester. The addition of the polyester allows for improved structural integrity within the yarn improving knittability, as well as providing stability and reducing shrinkage in the finishing process. This face provides an absorbing surface so that the moisture can effectively absorb for dispersion and evaporation.

[0053] After knitting, the textile was finished and processed by a Stenter Heatset, Beam Scour, and Stenter Dry (no finishing treatments / chemicals were used).

[0054] The combination of the technical front face, 3D filler and technical back face, as described, results in the very surprising and advantageous surface to surface moisture wicking effect.

[0055] The textile is flexible, breathable, with effective surface to surface moisture transfer, compression resistant, and with soft touch / feel.

[0056] Figures 3 to 9 illustrate the structure of the textile according to the disclosure.

[0057] Figure 3 depicts a simulated top-down view of the design of spacer textile of Example 2 from the polyester face i.e. the technical front of the fabric.

[0058] Figure 4 depicts a simulated top-down view of the design of spacer textile of Example 2 from the cellulosic face i.e. the technical back of the fabric.

[0059] Figure 5 depicts a magnified and simulated top-down view of the design of the spacer textile of Example 2 from the polyester face (i.e. the technical front of the fabric) with the cellulosic face omitted for clarity. Perforation holes for breathability are clearly visible.

[0060] Figure 6 depicts a magnified and simulated top-down view of the design of the spacer textile of Example 2 from the cellulosic face (i.e. the technical back of the fabric) with the polyester face omitted for clarity. Perforation holes for breathability are clearly visible.

[0061] Figure 7 depicts a cross-sectional simulated view of the design of the spacer textile of Example 2. The polyester face (the technical front of the fabric) is the top part of the image and the cellulosic face (the technical back of the fabric) is the bottom part of the image.

[0062] Table 1. Knitting specification for Examples 1 and 2.

[0063] Figure 8 depicts an enhanced simulated view of the design of the spacer textile of Example 2 with the high wicking polyester yams shaded blue to distinguish them from the poly cotton face (white). The use of high-wicking multifilament polyester filler yarns linking the polyester and cellulosic faces, provides a route for the moisture to wick along, with the moisture being transferred along the capillaries of the yarn.

[0064] Figure 9 is a photograph of spacer textile of Example 2 indicating the poly cotton face 20 and polyester face 10.

[0065]

[0066] Table 2: Yarn and threading details for Examples 1 and 2. In the yam details column, NNFnn refers to NN dtex, nn filaments.

[0067] Cellulosic / Polyester Blend was 240 dtex yam, 40% by weight compact spun cotton / 60% polyester yarn.

[0068] Results

[0069] The characteristics of the textiles were determined and the results presented in Table 3, below.

[0070] Comparative Example A was made from 100% standard polyester on both faces and standard monofilament filler yarns. Parameters such as CPI / WPI, thickness, perforations per inch are the same for Comparative Example A as for the spacer textile of Example 2.

[0071] Table 3 : data for textiles as produced in Examples 1 and 2 The spacer textiles were tested to determine the moisture wicking characteristics as set out below.

[0072] Indicative Fabrics Test Method Surface to Surface Moisture Transport Test

[0073] This test demonstrates the surface to surface moisture wicking characteristics of the textile. The textile is tested when horizontal / flat. A liquid dye is applied to one face of the textile. The liquid spread from the face on which the dyed liquid is applied is measured as is the spread of the bleed-through liquid on the other face.

[0074] Test Method

[0075] Sample Size: 70mm x 70mm

[0076] Fabric Parameters Fully Finished

[0077] Method

[0078] 2. Place the clean, fabric sample onto a flat, non-absorbent surface.

[0079] 3. Draw a small amount of dye liquid into a pipette

[0080] 4. Bring the pipette close to the surface of the fabric

[0081] 5. Release one droplet of dye onto the centre of the sample

[0082] 6. Wait for 120 seconds, then measure the liquid spread on the top and bottom face.

[0083] The results are shown in Figures 1 and 2.

[0084] Figure 1 depicts a spacer textile of Comparative Example A made from 100% polyester on both faces and standard monofilament filler yarns, showing (a) the face to which coloured dye was applied and (b) the other face.

[0085] Figure 2 depicts the (a), (b) polyester and (c ), (d) cellulosic faces of the spacer textile of Example 2, (a) with dye applied to the polyester face and showing (b) the cellulosic face; and (c ) with dye applied to the cellulosic face and (d) the polyester face. The appearance of the dye on the opposite face to that of dye application clearly demonstrates effective surface to surface moisture wicking, indicating that under real-world conditions moisture would move from one face to the other, thereby improving the thermophysiological comfort of the user.

[0086] Conclusion

[0087] The result of this study demonstrates the surface to surface moisture wicking properties of a spacer textile according to the disclosure (Examples 1 and 2). In contrast, the control spacer textile (Comparative Example A) does not transfer moisture away from the surface of the fabric, instead the moisture spreads over a large surface area; in a garment this would result in perspiration buildup between the user and the fabric.

[0088] The great advantage of the properties of wicking and transfer of moisture through the thickness of the fabric is of allowing the moisture to be drawn away from the skin, preventing moisture buildup and therefore improving the users thermophysiological comfort. The spacer textile of the disclosure may also have uses in applications such as apparel and other than apparel.

[0089] All publications mentioned in the above specification are herein incorporated by reference. Although illustrative embodiments of the invention have been disclosed in detail herein, with reference to the accompanying drawings, it is understood that the invention is not limited to the precise embodiment and that various changes and modifications can be performed therein by one skilled in the art without departing from the scope of the invention as defined by the appended claims and their equivalents.

Claims

CLAIMS1. A spacer textile comprising, a first layer comprising a moisture-wicking yarn, a second layer comprising a moisture-absorbing yarn, a plurality of wicking threads formed of a multi-filament yarn interconnecting the first layer and the second layer, and a plurality of resilient threads interconnecting the first layer and the second layer.

2. A spacer textile as claimed in claim 1, wherein the moisture wicking yam and / or the wicking threads comprise a yarn having at least a portion that is hydrophobic.

3. A spacer textile as claimed in claim 2, wherein the moisture wicking yam and / or the wicking threads comprise a yarn that absorbs 15% by weight or less water.

4. A spacer textile as claimed in any one of the preceding claims, wherein the moisture wicking yam and / or the wicking threads comprise a yarn having a wicking-enhancing cross section over at least a portion of the yam5. A spacer textile as claimed in claim 4, wherein the wicking enhancing cross section substantially comprises an n-foil cross section, wherein n is selected from one of 3, 4, 5, 6, or7.

6. A spacer textile as claimed in any one of the preceding claims, wherein the moisture wicking yam and / or the wicking threads comprise polyester, polyamide, or a mixture thereof.

7. A spacer textile as claimed in any one of the preceding claims, wherein the moistureabsorbing yam comprises a cellulosic yarn.

8. A spacer textile as claimed in claim 7, wherein the moisture-absorbing yam comprises 20 to 80% by weight of cellulosic yam.

9. A spacer textile as claimed in either claim 7 or claim 8, wherein the cellulosic yarn comprises cotton, optionally compact spun cotton.

10. A spacer textile as claimed in any one of the preceding claims, wherein the second layer further comprises multifilament polyester and / or multifilament polyamide yarn.

11. A spacer textile as claimed in any one of the preceding claims, wherein the resilient threads comprise monofilament polyester.

12. A spacer textile as claimed in any one of the preceding claims, wherein the textile thickness in the range 0.5 mm to 4 mm.

13. A spacer textile as claimed in any one of the preceding claims, wherein the spacer textile is warp knitted.

14. A method of making a spacer textile, the method comprising, a. forming a first layer comprising a moisture-wicking yarn, b. forming a second layer comprising a moisture-absorbing yam, c. connecting the first layer and the second layer with a plurality of wicking threads formed of a multi-filament yarn interconnecting the first layer and the second layer, and d. connecting the first layer and the second layer with a plurality of resilient threads interconnecting the first layer and the second layer.

15. A method as claimed in claim 14, wherein the method is a warp knitting method.

16. A method as claimed in either claim 14 or claim 15, further comprising one or more step(s) selected from stenter heatset, beam scour, and stenter dry.

17. A garment comprising a spacer textile as claimed in any one of the preceding claims.

18. A garment as claimed in claim 17, wherein the spacer textile is arranged in the garment so the first layer, when the garment is worn, is proximal the skin of the wearer.

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