Spacer fabric
The weft-knitted spacer fabric addresses the challenge of balancing comfort and support in garments by employing distinct fabric layers with varying yarn counts and structures, achieving enhanced user comfort and support through tailored properties.
Patent Information
- Application Number
- PCT/SG2025/050461
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2024-07-09
- Filing Date
- 2025-07-09
- Publication Date
- 2026-01-15
AI Technical Summary
Existing spacer fabrics lack the ability to provide both comfort and support effectively, particularly in garments like bras, due to uniform yarn thickness and knitting structures that compromise smoothness and cushioning.
A weft-knitted spacer fabric with distinct fabric layers having different yarn counts and knitting structures, where one layer is smoother and thinner with finer elastomeric yarns for skin contact, and another layer is thicker for support, combined with a filler yarn for stability, allowing tailored properties across zones.
Enhances comfort and support in garments by providing a smooth skin-facing layer and cushioning through varied yarn thickness and knitting structures, ensuring durability and shape retention.
Smart Images
Figure SG2025050461_15012026_PF_FP_ABST
Abstract
Description
[0001] SPACER FABRIC
[0002] Cross Reference to Related Application(s)
[0003] The present disclosure claims the benefit of Singapore Patent Application No. 10202402009S filed on 9 July 2024, which is incorporated in its entirety by reference herein.
[0004] Technical Field
[0005] The present disclosure generally relates to a spacer fabric. More particularly, the present disclosure describes various embodiments of a weft-knitted spacer fabric and a garment comprising the weft-knitted spacer fabric.
[0006] Background
[0007] Spacer fabrics are three-dimensional double-faced fabrics joined with spacer yarns to provide certain material properties, such as absorbency, breathability, resilience, and softness. 3D spacer fabrics are commonly used in various applications such as garments and medical textiles. For example, spacer fabrics are used in bras as they can provide better support and has cushioning effect similar to polyurethane foam cups.
[0008] Summary
[0009] According to a first aspect of the present disclosure, a weft-knitted spacer fabric is disclosed. The spacer fabric comprises: a first fabric layer knitted with a first main yarn and a first plating yarn plated to the first main yarn; a second fabric layer knitted with a second main yam and a second plating yarn plated to the second main yarn; and a filler fabric layer knitted with a filler yarn, the filler fabric layer knitted between the first and second fabric layers. The first and second fabric layers comprise different knitting structures, the knitting structure of the first fabric layer having more courses and / or wales per unit area than the knitting structure of the second fabric layer. One of the first main yam and first plating yarn comprises an elastomeric yam, and one of the second main yam and second plating yam comprises an elastomeric yam. The other of the first main yarn and first plating yarn is finer than the other of the second main yam and second plating yam, such that the first fabric layer is smoother, softer, and thinner than the second fabric layer.
[0010] According to a second aspect of the present disclosure, a garment comprising the spacer fabric is disclosed, wherein a skin-facing side of the garment comprises the first fabric layer.
[0011] A spacer fabric and a garment comprising the spacer fabric according to the present disclosure are thus disclosed herein. Various features and advantages of the present disclosure will become more apparent from the following detailed description of the embodiments of the present disclosure, by way of non-limiting examples only, along with the accompanying drawings.
[0012] Brief Description of Drawings
[0013] Certain embodiments of the present disclosure are described more fully hereinafter with reference to the accompanying drawings.
[0014] FIG. 1A and FIG. 1 B are illustrations of a spacer fabric according to embodiments of the present disclosure.
[0015] FIG. 2A and FIG. 2B are illustrations of knitted structures of the spacer fabric according to embodiments of the present disclosure.
[0016] FIG. 3A to FIG. 3D are illustrations of a filler layer of the spacer fabric according to embodiments of the present disclosure.
[0017] Detailed Description
[0018] For purposes of brevity and clarity, descriptions of embodiments of the present disclosure are directed to a spacer fabric and a garment comprising the spacer fabric in accordance with the drawings. While parts of the present disclosure will be described in conjunction with the embodiments provided herein, it will be understood that they are not intended to limit the present disclosure to these embodiments. On the contrary, the present disclosure is intended to cover alternatives, modifications and equivalents to the embodiments described herein, which are included within the scope of the present disclosure as defined by the appended claims. Furthermore, in the following detailed description, specific details are set forth in order to provide a thorough understanding of the present disclosure. However, it will be recognized by an individual having ordinary skill in the art, i.e. a skilled person, that the present disclosure may be practiced without specific details, and / or with multiple details arising from combinations of features of particular embodiments. In a number of instances, well-known systems, methods, procedures, and components have not been described in detail so as to not unnecessarily obscure features of the embodiments of the present disclosure.
[0019] In embodiments of the present disclosure, depiction of a given element or consideration or use of a particular element number in a particular figure or a reference thereto in corresponding descriptive material can encompass the same, an equivalent, or an analogous element or element number identified in another figure or descriptive material associated therewith.
[0020] References to “an embodiment / example”, “another embodiment / example”, “some embodiments I examples”, “some other embodiments / examples”, and so on, indicate that the embodiment(s) I example(s) so described may include a particular feature, structure, characteristic, property, element, or limitation, but that not every embodiment / example necessarily includes that particular feature, structure, characteristic, property, element or limitation. Furthermore, repeated use of the phrase “in an embodiment / example” or “in another embodiment / example” does not necessarily refer to the same embodiment I example.
[0021] The terms “comprising”, “including”, “having”, and the like do not exclude the presence of other features / elements I steps than those listed in an embodiment. Recitation of certain features I elements I steps in mutually different embodiments does not indicate that a combination of these features I elements I steps cannot be used in an embodiment. As used herein, the terms “a” and “an” are defined as one or more than one. The use of in a figure or associated text is understood to mean “and / or” unless otherwise indicated. The terms “first”, “second”, etc. are used merely as labels or identifiers and are not intended to impose numerical requirements on their associated terms.
[0022] Representative or exemplary embodiments of the present disclosure describe a spacer fabric 100 as shown in FIG. 1A and FIG. 1 B. More specifically, the spacer fabric 100 is manufactured by weft knitting and may be referred to as a weft-knitted spacer fabric 100. Weft knitting is a textile manufacturing process whereby horizontal rows or courses of loops are knitted across the width of the fabric. Suitable weft knitting machines may be used to manufacture the spacer fabric 100, such as the double bed or V-bed weft knitting machine.
[0023] Representative or exemplary embodiments of the present disclosure also describe a garment comprising the spacer fabric 100. For example, the garment includes bras, bra cups, garment cookies, and knee guards. The spacer fabric 100 may also be used in other textile products and in other applications, such as automotive and medical textiles.
[0024] The spacer fabric 100 includes a first fabric layer 110, a second fabric layer 120, and a filler fabric layer 130 knitted between the first fabric layer 110 and second fabric layer 120. The filler fabric layer 130 is knitted with a filler yam or spacer yam 132 that connects the first fabric layer 110 and second fabric layer 120 together and maintains stability and structural integrity throughout the spacer fabric 100. For example, the filler yarn 132 includes one or more of polyester, nylon, polypropylene, polylactic acid, viscose, rayon, cellulose, or protein fibre. For example, the filler yarn 132 has a yarn count from 20D to 150D.
[0025] The first fabric layer 110 is knitted with a first main yam 112 and a first plating yarn 114 plated to the first main yarn 112. As will be understood by the skilled person, the first main yam 112 and first plating yarn 114 run in line with each other, resulting in the first main yam 112 forming the technical face of the first fabric layer 110 and the first plating yarn 114, which is plated on the first main yam 112, forming the technical back of the first fabric layer 110. The second fabric layer 120 is knitted with a second main yarn 122 and a second plating yam 124 plated to the second main yarn 122. As will be understood by the skilled person, the second main yarn 122 and second plating yarn 124 run in line with each other, resulting in the second main yarn 122 forming the technical face of the second fabric layer 120 and the second plating yarn 124, which is plated on the second main yarn 122, forming the technical back of the second fabric layer 120.
[0026] For example, the first main yarn 112 and second main yarn 122 may include one or more of nylon, polyester, poly propylene, polylactic acid, cotton, viscose, rayon, wool, and covered yarn. For example, the covered yarn includes a core yarn (e.g. an elastomeric yarn) and a covering yarn (e g. nylon or polyester). For example, the first plating yarn 114 and second plating yarn 124 may include one or more of polyester, nylon, polypropylene, viscose, and rayon. Alternatively or additionally, the first plating yarn 114 and second plating yarn 124 may include an elastomeric yarn or a covered yarn. For example, the covered yarn includes an elastomeric core yarn (e.g. an elastomeric yarn) and a nylon or polyester covering yarn.
[0027] The spacer fabric 100 further includes elastomeric yarns that enhance stretch recovery, durability, and shape retention properties of the spacer fabric 100, ensuring that the spacer fabric 100 maintains its shape over repeated use, especially in garments such as bras. Specifically, each of the first fabric layer 110 and second fabric layer 120 includes elastomeric yarns. More specifically, one of the first main yarn 112 and first plating yarn 114 includes an elastomeric yarn, and one of the second main yarn 122 and second plating yarn 124 includes an elastomeric yarn.
[0028] Further, the other of the first main yam 112 and first plating yarn 114 is finer than the other of the second main yarn 122 and second plating yarn 124. For example, the finer yarn has a yam count of 30D to 150D, and the thicker yam has a yam count of 450D or more. It will be appreciated that a low yarn count means that the yarn fine fibres I filaments I threads and have lower weight density. The fine yarn may be hollow, such as by using hollow yarn fibres I filaments / threads or by using yams with hollow bubbles, to further reduce the weight density of the yam. In one embodiment, the first main yarn 112 includes an elastomeric yarn, the second main yarn 122 includes an elastomeric yarn, and the first plating yarn 114 is finer than the second plating yam 124. For example, the first plating yarn 114 has a yam count of 30D to 150D and the second plating yarn 124 has a yarn count of 450D or more. For example, the first plating yarn 114 and second plating yarn 124 include one or more of polyester, nylon, polypropylene, viscose, and rayon.
[0029] In one embodiment, the first main yarn 112 includes an elastomeric yam, the second plating yarn 124 includes an elastomeric yarn, and the first plating yarn 114 is finer than the second main yarn 122. For example, the first plating yam 114 has a yarn count of 30D to 150D and the second main yarn 122 has a yam count of 450D or more. For example, the first plating yarn 114 includes one or more of polyester, nylon, polypropylene, viscose, and rayon. For example, the second plating yam 124 includes a covered yarn having the elastomeric yarn as its core and a nylon or polyester covering yam.
[0030] In one embodiment, the first plating yarn 114 includes an elastomeric yam, the second main yarn 122 includes an elastomeric yarn, and the first main yarn 112 is finer than the second plating yarn 124. For example, the first main yarn 112 has a yam count of 30D to 150D and the second plating yarn 124 has a yarn count of 450D or more. For example, the second plating yam 124 includes one or more of polyester, nylon, polypropylene, viscose, and rayon. For example, the first plating yam 114 includes a covered yarn having the elastomeric yarn as its core and a nylon or polyester covering yam.
[0031] In one embodiment, the first plating yarn 114 includes an elastomeric yam, the second plating yam 124 includes an elastomeric yarn, and the first main yam 112 is finer than the second main yam 122. For example, the first main yam 112 has a yarn count of 30D to 150D and the second main yarn 122 has a yam count of 450D or more. For example, the first plating yarn 114 and second plating yarn 124 include a covered yarn having the elastomeric yam as its core and a nylon or polyester covering yarn.
[0032] Accordingly, when one of the first main yarn 112 and first plating yarn 114 includes an elastomeric yarn and one of the second main yarn 122 and second plating yam 124 includes an elastomeric yarn, the other of the first main yarn 112 and first plating yarn 114 is finer than the other of the second main yarn 122 and second plating yarn 124. The finer yarn of the first fabric layer 110 allows the first fabric layer 110 to be smoother and thinner than the second fabric layer 120.
[0033] When the spacer fabric 100 is used in a garment, the skin-facing side of the garment may include the first fabric layer 110, and the outward-facing side of the garment may include the second fabric layer 120. Being smoother and thinner, the first fabric layer 110 forms a smooth and soft surface that enhances comfort against the user’s skin, while the thicker second fabric layer 120 provides cushioning and support to the user’s body, especially for bra cups where comfort and support are important properties. The coarser yam of the second fabric layer 120 makes the spacer fabric 100 suitable for supportive or protective garments like knee guards.
[0034] Further, the first fabric layer 110 and second fabric layer 120 has different knitting structures. Specifically, the knitting structure of the first fabric layer 110 has more courses and / or wales per unit area than the knitting structure of the second fabric layer 120. As the first fabric layer 110 has finer yarns than the second fabric layer 120, smaller loops can be formed by the finer yams in the first fabric layer 110 compared to larger loops formed by the coarser yams in the second fabric layer 120. Smaller loops improve comfort and achieve smooth hand feel while larger loops provide effective cushioning and support. The ratio of the number of courses / wales per unit area between the first fabric layer 110 and second fabric layer 120 may be varied to adjust various properties of the spacer fabric 100, such as to adjust comfort, performance, and fabric stability properties. For example, the number of courses and / or the number of wales per unit area in the knitting structures have a ratio of 1.5:1 , 2:1 , or 3: 1 between the first fabric layer 110 and second fabric layer 120.
[0035] FIG. 2A and FIG. 2B show examples of the knitting structures of the spacer fabric 100. For example in the first knitting structure 210 shown in FIG. 2A, the second fabric layer 120 has tuck stitches that provide additional yarn length and allow for greater widthwise stretchability. For example in the second knitting structure 220 shown in FIG. 2B, the second fabric layer 120 has floats or miss stitches which restrict stretchability due to the floating sections that limit movement. Accordingly, the first knitting structure 210 achieves higher stretchability compared to the second knitting structure 220 due to the presence of tuck stitches that enable more stretch and flexibility in the spacer fabric 100.
[0036] As described above, the filler yarn 132 of the filler fabric layer 130 connects the first fabric layer 110 and second fabric layer 120 to each other. Preferably, as shown in FIG. 3A and FIG. 3B, the filler yarn 132 is a fine yarn with a low yam count, such as 20D to 150D. A finer filler yarn 132 requires less space 300 to accommodate between adjacent loops of the yarns in the first fabric layer 110 and second fabric layer 120. The loops along a course 310 are more closely packed together and the space or gaps 300 between the wales 320, which are perpendicular to the courses 310, are smaller, resulting in a smoother and flatter surface with better hand feel.
[0037] In contrast, as shown in FIG. 3C and FIG. 3D, a coarser filler yarn 132 requires more space 300 to accommodate between adjacent loops of the yarns in the first fabric layer 110 and second fabric layer 120. The loops along a course 310 are wider apart and the space or gaps 300 between the wales 320 are larger, resulting in a rougher surface with poor hand feel.
[0038] In some embodiments, the spacer fabric 100 includes a plurality of zones having different knitting structures, wherein the zones exhibit different material properties from each other, such as different modulus and stretchability in different zones. For example, different yarn materials may be used in any one or more of the respective layers 110,120,130 of the various zones. Alternatively or additionally, the knitting structures of the zones may include different combinations of knits, tucks, floats, and number of courses / wales per unit area for any one or more of the respective layers 110,120,130. For example, shorter / tighter loops increase the modulus while longer / slacker loops decrease the modulus. Further alternatively or additionally, the knitting structures of the zones may have different lengths of each knitted loop.
[0039] Specific zones with different material properties can thus be created in the spacer fabric 100, such as nipple concealment areas, high modulus areas, and highly stretchable areas. This allows for tailored functionality within the spacer fabric 100 and enhances the fabric’s versatility and utility across various textile applications. In the foregoing detailed description, embodiments of the present disclosure in relation to a spacer fabric and a garment comprising the spacer fabric are described with reference to the provided figures. The description of the various embodiments herein is not intended to call out or be limited only to specific or particular representations of the present disclosure, but merely to illustrate non-limiting examples of the present disclosure. The present disclosure serves to address at least one of the mentioned problems and issues associated with the prior art. Although only some embodiments of the present disclosure are disclosed herein, it will be apparent to a person having ordinary skill in the art in view of this disclosure that a variety of changes and / or modifications can be made to the disclosed embodiments without departing from the scope of the present disclosure. Therefore, the scope of the disclosure as well as the scope of the following claims is not limited to embodiments described herein.
Claims
Claims1 . A weft-knitted spacer fabric comprising: a first fabric layer knitted with a first main yarn and a first plating yarn plated to the first main yarn; a second fabric layer knitted with a second main yarn and a second plating yarn plated to the second main yarn; and a filler fabric layer knitted with a filler yarn, the filler fabric layer knitted between the first and second fabric layers, wherein the first and second fabric layers comprise different knitting structures, the knitting structure of the first fabric layer having more courses and / or wales per unit area than the knitting structure of the second fabric layer; wherein one of the first main yarn and first plating yarn comprises an elastomeric yarn, and one of the second main yam and second plating yarn comprises an elastomeric yarn; and wherein the other of the first main yarn and first plating yarn is finer than the other of the second main yam and second plating yam, such that the first fabric layer is smoother, softer, and thinner than the second fabric layer.
2. The spacer fabric according to claim 1 , wherein the courses and / or wales per unit area in the knitting structures have a ratio of 1.5:1 , 2:1 , or 3:1 between the first and second fabric layers.
3. The spacer fabric according to claim 1 or 2, wherein the other of the first main yarn and first plating yarn comprises a yarn count of 30D to 150D.
4. The spacer fabric according to any one of claims 1 to 3, wherein the other of the second main yarn and second plating yarn comprises a yarn count of 450D or more.
5. The spacer fabric according to any one of claims 1 to 4, wherein the filler yarn comprises a yam count from 20D to 150D.
6. The spacer fabric according to any one of claims 1 to 5, wherein the filler yarn comprises one or more of polyester, nylon, polypropylene, polylactic acid, viscose, rayon, cellulose, or protein fibre.
7. The spacer fabric according to any one of claims 1 to 6, further comprising a plurality of zones having different knitting structures, wherein the zones exhibit different material properties from each other.
8. The spacer fabric according to claim 7, wherein the knitting structures of the zones comprise different combinations of knits, tucks, floats, and number of courses and / or wales per unit area for any one or more of the respective layers.
9. A garment comprising the spacer fabric according to any one of claims 1 to 8, wherein a skin-facing side of the garment comprises the first fabric layer.