A seamless multi-zone fabric with unique knitting patterns of insecticide incorporated polymer filaments

Abstract

The present invention relates to unique seamless multizone fabric knitting patterns of insecticide incorporated polymer matrix filaments The present invention also relates to a method of making the unique fabric knitting patterns from monofilaments having incorporated insecticidal composition in polymer matrix. Said uniquely knitted pattern of fabric is useful for making insect / pests protective nets or insecticide treated nets (ITNs) or long-lasting insecticidal net (LLIN) with enhanced durability and improving user acceptance.

Description

[0001] A SEAMLESS MULTI-ZONE FABRIC WITH UNIQUE KNITTING PATTERNS OF INSECTICIDE INCORPORATED POLYMER FILAMENTS

[0002] FIELD OF THE INVENTION

[0003] The present invention relates to multi-zone fabric with unique knitting patterns integrated together in a seamless fabric of insecticidal incorporated polymer filaments.

[0004] More particularly, the present invention relates to novel and innovative polymer filament fabric with multi-zone design made by unique knitting patterns and integrated together into seamlessly manufactured textile fabric. These polymer filaments possess an incorporated insecticidal composition in the polymer matrix, useful for making insecticidal - treated Nets (ITN) or long-lasting insecticidal nets (LLIN) more effective and with improved durability and user acceptance. Further, the present invention relates to a rectangular shaped insecticidal treated net (ITN), comprising side panels constructed from seamlessly connected multi-zone mesh fabrics with unique knitting patterns.

[0005] BACKGROUND OF THE INVENTION

[0006] Apart from introduction of new chemical compounds to overcome insecticidal resistance, during the past two decades, ITNs remained physically the same and not much has been attempted to improve the physical and mechanical characteristics. ITNs are treated with insecticides where the insecticide is coated around or incorporated into the filaments. The nets typically resist multiple washes, and its biological activity lasts as long as the net itself. The use of insecticidal net is a prevention tool that prevents transmission of vector borne diseases, i.e., fewer humans get infected with the malaria protozoan parasite because the ITNs reduce the probability of mosquitoes biting humans to get infected with the parasite or survive long enough to become infectious and then bite another human.

[0007] ITNs are known reported to be responsible for about 75% of the reduction in malaria prevalence in children across endemic Africa between 2000 and 2015 (Nature 2015; 526(7572): 207-11). Since then, these gains have diminished and the African Region as a whole is off track for 2025 WHO malaria milestones by about 50% (World Health Organization, Geneva. World Malaria Report 2023. (2023). At present, significant hope rests on the idea of ‘dual active ingredient (dual Al)’ ITNs, treated with 2 insecticides with different mode of action to revert these adverse trends, that are, in part, related to the spread of pyrethroid insecticide resistance.

[0008] ITN coverage has remained largely unchanged since 2015, a trend that coincided with the stagnation of global malaria reduction (World Health Organization, Geneva. World Malaria Report 2023. (2023). New dual Al ITNs have a stronger impact on malaria transmission in areas with pyrethroid resistance, but the added benefit is lost after 2 years, when the coverage, and therefore usage, of these nets became too low to exert population level effects on mosquitoes (Accrombessi M, Cook J, Dangbenon E, et al. Effectiveness of pyriproxyfen-pyrethroid and chlorfenapyr-pyrethroid long-lasting insecticidal nets (LLINs) compared with pyrethroid-only LLINs for malaria control in the third year post-distribution: a secondary analysis of a cluster-randomized controlled trial in Benin. The Lancet Infectious Diseases 2024). ITN effectiveness should increase if longevity of the active ingredients and physical integrity of ITNs are enhanced.

[0009] Typically, an ITN has a rectangular shape, consisting of 4 side panels and 1 roof panel (Fig. 10). Despite the physical property requirements being different over the total ITN surface, the densities and knitting patterns are normally the same in all panels of an ITN. The problem to be solved by the present invention is to design an ITN, which is addressing the need of individual areas of the net and provide unique physical and mechanical characteristics in different zones of the ITN in order to enhance durability and lifetime of the ITN, while at the same time enhance user convenience and acceptance.

[0010] While the bio efficacy of insecticidal compounds used in insecticide-treated nets (ITNs) is extensively covered in the prior art and addressed in the present invention, ITNs must also fulfill a range of physical, mechanical, financial, and logistical requirements, many of which are inherently contradictory.

[0011] Examples of Contradictory Requirements:

[0012] 1. Mechanical Durability:

[0013] ITNs are expected to withstand up to 3 years of field use. This durability is typically achieved with thick and heavy monofilaments (>150 denier), which introduce the following drawbacks:

[0014] • Increased weight, leading to higher material (plastic) costs. • Larger packing volume, as heavy-denier warp-knitted fabrics are less compressible, resulting in reduced shipping efficiency and increased logistics costs.

[0015] • Reduced user comfort, due to rougher, stiffer textures that feel unpleasant during skin contact.

[0016] 2. Soft Touch / User Comfort:

[0017] Users often prefer softer ITNs that provide a more comfortable sleeping experience. Softer textures are usually achieved with multifilament yams, but these introduce their own challenges:

[0018] • Reduced air permeability, as textured multifilament mesh fabrics restrict airflow more than monofilament meshes, leading to higher temperatures and reduced comfort in warm climates (see Fig. 12).

[0019] • Lower abrasion resistance, resulting in decreased product durability and shorter lifespan.

[0020] These observations reveal the inherent trade-off between durability and comfort in existing ITN designs. While monofilament-based nets offer durability and ventilation, they lack softness. Conversely, multifilament-based nets provide comfort but underperform in durability and breathability.

[0021] More particularly, the present invention relates to novel and innovative polymer filament fabric embedded seamlessly with multi-zones with unique knitting patterns. These polymer filaments incorporate an insecticidal composition in the polymer matrix, useful for making insecticidal -treated nets (ITN) or long-lasting insecticidal nets (LLIN) more effective and long-lasting.

[0022] The insecticide incorporated material that can be used for longer lasting ITNs with unique fabric knitting patterns which have improved control of release of active ingredient(s) such as-insecticide(s) or biocide(s) from such incorporated insecticidal compositions over long time and are more stable under storage conditions in addition to having improved physical characteristics to reduce hole formation and improve user retention over time. For ease of use and understanding, we are using the terminology Insecticide / Insecticidal Treated Nets (ITN) interchangeably with respect to Long Lasting Insecticidal Nets (LLIN).

[0023] Matthieu Zellweger et al in WO2011124227A1 discloses a method of providing longterm stability to alkali sensitive biocides in polypropylene products by incorporating biocides such as deltamethrin with acid into a polymer matrix comprising polypropylene. An article comprising a thermoplastic polypropylene polymer matrix having a biocide and an acid dispersed throughout the polymer matrix. The article is a multifilament yarn from which can be used for preparing mosquito nets.

[0024] Disclosure in website https: / / coregroup. org wp-conlenl uploads mediabackup docitmenls meeting reports Angola Malaria 2009 e permanel 3 mosquito

[0025] _net combination.pdf highlights the use of two different zones, wherein the roof of Perma Net ® 3.0 is polyethylene fiber with 100 Denier monofilament containing Deltamethrin embedded within the filament. The upper side of net is a multifilament polyester fiber 75 Denier with a load of Deltamethrin (about 85 mg / m2) and the lower side of net is a multifilament polyester fiber 75 Denier with a special design with the crown strengthened for added durability, with a load of about 115 mg / m2 Deltamethrin. The strengthening of the lower side of the net fabric in this design is achieved by only doubling the yam. The weakness of this approach is that the knitting pattern still remains the same with limited additional robustness to the fabric’s knitting pattern.

[0026] In a similar disclosure in the website: https: / / www.adiwara.com / permanet-3-0 / , it shows two stitched conventional zones, wherein top zone or panel is polyethylene fiber based while lower panel composed on polyester fibers.

[0027] In the knitting pattern, conventionally, there are two bars (or filaments of polymer) knitted as warp knitting pattern to make the mosquito bed nets fabric, however, such conventional warp knitted mono-pattern LLIN fabrics have been observed over the time with following setbacks while in continuous use, e.g. Integrity loss of knitted fabrics leading to loosening or hole formation Safety of the user is compromised while using Fabric is treated externally as coated with insecticide The effect of AIs (Insecticide) is also compromised Among the well-known challenges for LLINs (Long Lasting Incorporated Nets)-the following are the key considerations

[0028] 1. Durability of Net

[0029] 2. Usability of Nets owing to damage while in use

[0030] 3. The less soft feel of the netting fabric made of monofilaments

[0031] 4. Insufficient ventilation caused by limited air permeability through fabrics made in Multifilament Technology

[0032] 5. During the summer season, there is a more profound impact owing to less usage of the nets due to discomfort and etc.

[0033] Despite of vast literature and the development of various mosquito bed nets incorporating numerous insecticidal compounds from different chemical classes, significant challenges and limitations persist. Conventional use of these nets by humans has revealed issues that necessitate the rediscovery and innovation of long-lasting, affordable alternatives. These setbacks highlight the urgent need for novel, cost-effective, safe, and reliable vector control methods with enhanced user acceptance. Such approaches must address the shortcomings of existing solutions, as acknowledged in the prior art, and offer improved protection against vectors like mosquitoes and other insects.

[0034] Inventors of the present application have attempted to address the setbacks and existing challenges by developing fabric netting embedded with seamlessly integrated multi-zones with unique knitting patterns using 2-4 warp knitting ground bars with insecticidal- incorporated polymer monofilaments.

[0035] More particularly, the present invention provides a novel and innovative polymer filament fabric with a multi-zone combination of unique knitting patterns. These polymer yams possess incorporated insecticidal composition in the polymer matrix useful for making insecticidal treated Nets (ITN) more effective and durable with improved user acceptance.

[0036] OBJECT OF THE INVENTION

[0037] The main object to the present invention is to provide unique fabric knitting patterns of insecticidal incorporated polymer filaments. More particularly, the present invention provides a novel and innovative polymer filament fabric with multi-zones combination of unique knitting patterns. These polymer filaments possess incorporated insecticidal composition in the polymer useful for making insecticidal treated nets (ITN) more effective and durable with improved user acceptance.

[0038] Another object of the present invention is to provide nets, constructed from seamlessly connected multi-zone fabrics with unique knitting pattern designed to offer enhanced durability, improved airflow, soft touch feel, and superior user comfort and acceptance.

[0039] Another object of the present invention is to provide insecticidal treated nets by integrating the advantages of both monofilament and multifilament fabric structures within a single, cost-effective, and manufacturable ITN design. This is achieved by segmenting the ITN into multiple functional surface zones, each optimized for the specific mechanical and physical requirements relevant to its location and use.

[0040] A specific object of the present invention is to provide a rectangular-shaped insecticide-treated net (ITN) comprising side panels made from seamlessly connected multi - zone mesh fabrics with a unique knitting pattern, treated with at least one insecticide for enhanced protective efficacy.

[0041] SUMMARY OF THE INVENTION

[0042] The present invention relates to unique fabric knitting patterns of insecticidal incorporated polymer filaments.

[0043] More particularly, the present invention relates to novel and innovative polymer yarn fabric with multi-zone combination of unique knitting patterns. These polymer filaments possess incorporated insecticidal composition in the polymer matrix useful for making insecticidal treated Nets (ITN) more effective and durable with improved user acceptance.

[0044] The present invention provides an ITN with multi-zone side panels, each tailored to its functional role. These zones:

[0045] • Are warp-knitted into mesh fabrics using monofilament yarns, • Feature distinct knitting patterns and yarn threading to optimize softness, strength, and breathability,

[0046] • Are seamlessly integrated during manufacture, ensuring structural integrity and production efficiency.

[0047] This zoned construction allows the ITN to achieve a balanced combination of durability, ventilation, user comfort, and cost-effectiveness, addressing long-standing limitations of conventional single-pattern ITNs.

[0048] The present invention also relates to a multi-zone uniquely knitted insecticidal treated net (ITN) fabric comprising: a) a first zone designated as zone-1, wherein the zone-1 is compacted knitted pattern having weight range between 45-90 GSM; b) a second zone designated as zone-2, wherein the zone-2 is light compacted knitted pattern having weight range between 23-55 GSM; c) a third zone designated as zone-3, wherein the zone-3 is light knitted having weight range between 20-50 GSM;

[0049] This multi-zone uniquely knitted insecticidal treated net (ITN) fabric according to the present invention is comprising of at least two zones and the first zone is necessarily the Zone-1 as compactly knitted having weight range between 50-80 GSM. GSM stands for weight in grams per square meter, which refers to the weight of a fabric. In general terminology, it is to be understood that the higher a fabric's GSM, the thicker and more hard- wearing it's likely to be.

[0050] The present invention also relates to a multi-zone uniquely knitted insecticidal treated net (ITN) fabric, wherein the insecticide treated nets (ITNs) is produced by a warp knitting process from insecticide incorporated monofilament yarn extruded out of polymer and have a linear density ranging between 70 to 200 denier.

[0051] In a particular aspect, the present invention also relates to a three-zone uniquely knitted insecticidal treated net (ITN) fabric according to FIG.-l and FIG. -2 comprising: a) Zone-1 is formed by compacted knitting pattern having weight range between 45-90 GSM; and knitted using at least 2 ground bars. b) Zone-2 is formed by a less compacted knitting pattern having weight range between 27-50 GSM; and knitted using at least 2 ground bars. c) Zone-3 is formed by a light knitting pattern having a weight range between 23-50 GSM; and knitted using at least 2 ground bars.

[0052] Further, according to the present invention, three zones are uniquely knitted in the insecticidal-treated net (ITN) fabric in such a way that all three zones are knitted well integrated with seamless interfaces between each zone, according to and FIG. 9.

[0053] The present invention also relates to a multi-zone uniquely knitted insecticidal treated net (ITN) fabric, wherein, zone-1 comprises the lower 0-45 cm, designed for abrasion resistance, zone-2 comprises 20-80 cm height for soft-touch user contact, and zone-3 comprises the upper 50-220 cm for ventilation.

[0054] The unique fabric with seamless multi-zone knitting patterns of insecticidal incorporated polymer matrix of monofilaments can be useful in making more affordable and more effective ITNs with moderate or lesser insecticidal loading / incorporation of highly expensive insecticides / pesticides (viz, Spinosad, Emamectin, Spinoteram, Milbemectin, Doramectin, Eprinomectin, Ivermectin, Selamectin, Milbemycin oxime, Moxidectin, Lepimectin, Nemadectin, Bifenthrin, Etofenprox, Chlorantraniliprole, Cyanoantraniliprole, Chlorfenapyretc as per the need of loading / incorporation in the well exposed areas of nets.

[0055] The monofilaments of polymer matrix with incorporated insecticide may be selected from but not limited to Bifenthrin, Permethrin, Indoxacarb, Spinosad, Emamectin, Spinoteram, Metaflumizone, Tolfenpyrod, Etofenprox, lambda-Cyhalothrin, alpha Cypermethrin, Deltamethrin or Chlorfenapyr.

[0056] These monofilaments may optionally contain an organic synergist selected fromPiperonyl butoxide (PBO) or o-cresol derivatives.

[0057] They may also optionally contain an Insect Growth Regulator (IGR) selected from pyriproxifen, novaluron, fenoxycarb, kinoprene, methoprene, hydroprene, Tebufenozide, methoxyfenozide, halofenozide, and chromafenozide

[0058] The above objects and advantages of the present invention will become apparent from the detailed description and working examples of the invention described below.

[0059] The warp knitted insecticidal fabric of the present invention is utilized to make ITNs or LLINs having advantages of improved effectiveness of insecticidal activity besides long-lasting activity along with improved human safety and acceptance.

[0060] BRIEF DESCRIPTION OF THE DRAWINGS

[0061] FIG. 1 is an exemplified illustration of Insecticidal Treated Net (ITN) fabric knitted with polymeric monofilaments with three zones integrated knitting pattern. This unique knitting pattern of three zones is with seamless interfaces between them.

[0062] FIG. 2 is an exemplified illustration of ITN with unique pattern of seamless interface of all three zones (Far view)

[0063] FIG. 3 is an exemplified illustration of knitting pattern of zone-1 (A) and seamlessly integrated with Zone-2 (B)

[0064] FIG. 4 is an exemplified illustration of knitting pattern of zone-2 - A Closer view.

[0065] FIG. 5 is an exemplified illustration of knitting pattern of zone-2 - A Distant view.

[0066] FIG. 6 is an exemplified illustration of Integrated knitting pattern view of zone-1 and zone-2 with seamless interface between zones

[0067] FIG. 7 is an exemplified illustration of knitting pattern of zone-3 - A Closer view.

[0068] FIG. 8 is an exemplified illustration of knitting pattern of zone-3 - A Distant view.

[0069] FIG. 9 is an exemplified illustration of Integrated knitting pattern view of zone-2 and zone-3 with seamless interface between zones

[0070] FIG. 10 is an exemplified illustration of three-dimensional (3D) representation of rectangular shape nets

[0071] FIG. 11 is an exemplified illustration of cross-section representation of rectangular shape nets FIG. 12 Air permeability test results

[0072] FIG. 13 is an exemplified illustration of zone-2, zone-3 and zone-4 ITN with unique pattern of seamless interface of all three zones

[0073] FIG. 15 Graphs indicating Tactile Sensation Analyzer (TSA) Results of Outside ITN Surface and Inside ITN Surface

[0074] FIG. 16 is an exemplified illustration of two zone side panels

[0075] FIG. 17 is an exemplified illustration of three zone side panels

[0076] DESCRIPTION OF THE INVENTION

[0077] The present invention will now be described here in after with reference to the accompanying data in which a preferred embodiment of the invention is shown. This invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough, and will fully convey the scope of the invention to those skilled in the art.

[0078] The present invention now will be described hereinafter with reference to the detailed description, in which some, but not all embodiments of the invention are indicated. Indeed, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, the embodiments are provided so that this disclosure will satisfy applicable legal requirements. The present invention is described fully herein with non-limiting embodiments and exemplary experimentation.

[0079] The present invention will now be described hereinafter with reference to the accompanying drawings in which a preferred embodiment of the invention is shown. This invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough and will fully convey the scope of the invention to those skilled in the art.

[0080] The foregoing definitions provided herein for the terminologies used in the present disclosure are for illustrative purpose only and in no manner limit, the scope of the present invention disclosed in the present disclosure. It will be understood that the terminology used herein is for the purpose of describing embodiments only and is not intended to be limiting. As used in this specification, the singular forms "a", "an" and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, the reference to "a net" includes one or more of such nets and it is interchangeable with each other.

[0081] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one ordinary skilled in the art to which the invention pertains. Although other methods and materials similar, or equivalent, to those described herein can be used in the practice of the present invention, the preferred materials and methods are described herein.

[0082] The term “combination” can be replaced with the words “mixture” or “composition”, or “formulation” defined or refers to as combining two or more active ingredients formulated in desired formulations.

[0083] As used herein, the term "multi-zone" refers to a structural configuration of a fabric or material that comprises two or more distinct regions or zones, each differing in one or more physical, structural, or functional characteristics. These differences may include, but are not limited to, knitting or weaving patterns, fabric weight (GSM), mesh geometry, filament composition, denier, tensile strength, thickness, height, coating or treatment type, and / or the type or concentration of active agents such as insecticides. In the context of insecticidal -treated nets (ITNs), "multi-zone" denotes a fabric wherein each zone is specifically designed to serve a distinct function-for example, providing enhanced durability in tucking area, soft touch feel in bodycontact region, improved ventilation in peripheral area, or differential insecticidal treatment depending on vector contact probability.

[0084] As used herein, the term "warp-knitted" refers to a method of fabric construction in which the yarns run longitudinally (in the warp direction) and are interloped in a zigzag fashion along the length of the fabric. In warp knitting, each needle loops its own thread, and the resulting fabric is formed by the simultaneous knitting of all loops in parallel columns, producing a stable, non- raveling mesh structure.

[0085] The term “compact knitting pattern” refers to a warp-knitted fabric structure characterized by a high stitch or loop density per unit area, typically resulting in a fabric with a weight in the range of 45 to 90 grams per square meter (GSM). Such compact patterns are produced by full threading of two or more guide bars and involve short lapping movements to create tightly packed meshes. Compact patterns offer enhanced mechanical strength, abrasion resistance, and durability.

[0086] The term “light knitting pattern” refers to a warp-knitted fabric structure characterized by a lower stitch or loop density, resulting in a fabric with a weight in the range of 20 to 50 GSM. These patterns are produced using fewer overlapping loops, open mesh lapping geometries, and partial or 1-in-l-out threading of guide bars. Light knitting patterns are designed to maximize breathability, flexibility, and airflow, particularly in ventilation zones.

[0087] The term “soft touch” refers to a fabric property characterized by a smooth, gentle, and low-friction tactile sensation when the fabric surface comes into contact with human skin. In the context of the present invention, soft-touch is imparted by a specific warp knitting pattern that produces a moderate-density mesh with reduced surface roughness, typically achieved through:

[0088] • One-in-one-out or partial threading configurations of the guide bars,

[0089] • Controlled lapping movements,

[0090] • The use of finer denier monofilaments or elastically responsive yarns.

[0091] The soft-touch surface is intended to enhance user comfort during prolonged contact and is particularly suitable for the body-contact zone (Zone-2) of the insecticidal net. The soft-touch characteristic may be measured using a tactile surface analyzer, such as the EMTEC Tactile Sensation Analyzer (TSA), where lower TS7 values (e.g., 20-35 RMS) are indicative of increased surface softness.

[0092] The term “unique knitting pattern ” refers to a zone-specific warp-knitting configuration that differs from conventional or repetitive mesh structures by virtue of its guide bar lapping movements, threading mode, loop geometry, yarn feed rate, or a combination thereof. Unique patterns are designed to impart functional attributes such as softness, tensile strength, abrasion resistance, or breathability to specific zones of the net fabric. These patterns are tailored to user needs and enable the seamless integration of multiple functional zones within a single knitted structure. The term “control” or “controlling” or “prevent” or “preventing” or “kill” or “killing” an insect pests refer to inhibiting or reducing the growth, reducing the ability of insect pests to grow or reproduce or proliferate or spread, including killing (e.g., causing the morbidity or mortality, or reduced fecundity) of insects and insect eggs and larvae.

[0093] As used herein, the terms "comprises", "comprising", "includes", "including", or any other variation thereof, are intended to cover a non-exclusive inclusion, subject to any limitation explicitly indicated. For example, a composition or a method that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such composition, or method.

[0094] As used herein, the term "net" may be used interchangeably with but not limit to terms like “article” or “barrier” or “mosquito net” or “insect -treated net (ITN)” or “bed net” depending on the context. Such terminology shall not be limit the scope of the invention and encompasses any structured construct capable of performing equivalent functions, particularly those relating to vector control or user protection.

[0095] As used herein, the term "net" refers to a textile structure comprising an interconnected array of yarns, filaments, or threads configured to form a porous, open-mesh fabric. The net may be formed by knitting, weaving, knotting, or extrusion processes and is characterized by defined mesh openings that permit airflow while providing a physical or functional barrier. The structure may be manufactured using monofilament or multifilament polymeric materials and may vary in terms of mesh geometry, strand thickness, fabric weight (e.g., in grams per square meter), and mechanical properties. The net is suitable for applications requiring ventilation, visibility, and exclusion of external agents, such as insects, debris, or particulates.

[0096] The term “synergism” as used in this specification refers to the interaction between two or more active compounds or other factors to produce a combined effect greater than the sum of their separate effects. The present invention involves the mixture of two active ingredients which has increased efficacy when compared to individual use and admixture of those components.

[0097] The expression of various quantities in terms of “% or “%” means the percentage by weight, relative to the weight of the total solution or composition unless otherwise specified. Unless otherwise specified, % refers to % weight; and % weight refers to % of the weight of the respective component with respect to the total weight of the composition.

[0098] The term “Impregnation” or “Incorporation" as used in this specification is a process for applying the insecticide composition. This process may include a process for curing the applied insecticide composition to achieve a coating onto the non-living material, if desired. An "impregnated non-living material" is a material onto which the insecticide composition is applied. The "impregnated non-living material" may be coated by curing the applied insecticide composition, if desired.

[0099] The term "Seamless," as used in the present invention, refers to a method of fabric construction wherein multiple zones with differing knitting patterns or fabric densities are integrally formed in a single continuous manufacturing process using warp knitting techniques, without the use of stitching, sewing, adhesive bonding, or mechanical attachment between adjacent zones. This integration is achieved through programmable guide bar movement and yarn feed variation on a warp knitting machine, resulting in a unified fabric structure with no physical seams, joints, or discontinuities at the interfaces between zones.

[0100] The term “non-living substrate” as used in this specification preferably refers to a textile material or plastics material selected from the group consisting of yarn, filaments, fibers, fabric, knit goods, nonwovens, netting material, foils, tarpaulins and coating compositions. The netting material may be prepared by any method known in the art, for example by circular knitting or warp knitting, or by sewing parts of a netting to obtain the desired netting.

[0101] The textile material or plastics material may be made from a variety of natural and synthetic fibers, also as textile blends in woven or non-woven form, as knit goods, yarns or fibers. Natural fibers are for example cotton, wool, silk, jute or hamp. Synthetic fibers are for example polyamides, polyesters, polyacryl nitrites, polyolefins, for example polypropylene or polyethylene, Teflon, and mixtures of fibers, for example mixtures of synthetic and natural fibers. Polyamides, polyolefins and polyesters are preferred. The term non-living material also discloses non-textile substrates such as coating compositions, leathers, synthetic adaptions of leather, flocked fabrics, sheetings, foils and packaging material. Further, the term non-living material discloses cellulose- containing materials e.g. cotton materials such as garment or cotton nets and also wooden materials such as houses, trees, board fences, sleepers and also paper.

[0102] Furthermore, the term non-living material also discloses protective window and closet gratings or grills made from suitable metals. Preferably, the non-living material is a textile material or plastics material as mentioned above. Most preferred are nettings made from polyester, especially polyethylene terephthalate. In a further preferred embodiment, the non-living material is a cellulose containing non-living material.

[0103] The non-living material may be textile material or plastics material in form of coverings, for example bedclothes, mattresses, pillows, duvets, cushions, curtains, wall coverings, carpeting and window, cupboard and door screens. Further typical textile materials or plastics materials are geotextiles, tents, inner soles of shoes, garments, such as socks, trousers, shirts, i.e. preferably garments, e.g. uniforms, used in body areas exposed to insecticide bites and the like as well as horse blankets. The nettings are for example used as bed nets, for example mosquito nets, or for covering or as nets in agriculture and viniculture. Other applications are movable fences for the protection of humans and animals against air-borne low-flying insects. Fabrics or nettings may be used for packages, wrapping sacks, containers for food, seeds and feed thus protecting the material from attack by insects but avoiding direct contact with the insecticide -treated nets or fabrics.

[0104] As represented in Fig. 10, the invention proposes an ITN comprising multi-zone side panels, with a minimum of two preferably three or more zones. Each zone is warp-knitted using monofilaments in specific mesh patterns and threading styles, seamlessly integrated within a single manufacturing process. The distinct zones and their corresponding performance criteria are outlined below:

[0105] 1. Roof Panel:

[0106] • Mechanical Durability: Low relevance; minimal user contact during use.

[0107] • Ventilation Capability: High relevance; facilitates upward escape of warm air from the sleeping area.

[0108] • Soft Touch: Not relevant; no body contact.

[0109] 2. Side Panel - Zone 3 (Ventilation Zone):

[0110] Mechanical Durability: Low relevance; limited user contact. • Ventilation Capability: High relevance; complements roof panel to promote airflow.

[0111] • Soft Touch: Not relevant; no body contact.

[0112] 3. Side Panel - Zone-2 (Body Contact Zone):

[0113] • Mechanical Durability: High relevance; direct user contact increases susceptibility to damage.

[0114] • Ventilation Capability: Low relevance; this zone contributes minimally to overall ventilation.

[0115] • Soft Touch: High relevance; in direct contact with the user during sleep.

[0116] 4. Side Panel - Zone-1 (Bottom Zone):

[0117] • Mechanical Durability: High relevance; prone to abrasion and snagging.

[0118] • Ventilation Capability: Not relevant; typically covered by a mattress.

[0119] Soft Touch: Not relevant; no body contact. The embodiment of the present invention provides unique fabric knitting patterns of insecticidal incorporated polymer filaments.

[0120] The embodiment of the present invention particularly provides novel and innovative knitted fabric comprising multizone, with each zone having a unique fabric pattern made of polymer filaments. The polymer filament has an incorporated insecticidal composition in the polymer matrix, useful for making insecticidal-treated nets (ITN) more effective and long- lasting with improved user acceptance.

[0121] In one embodiment according to the present invention, it provides a multi -zone uniquely knitted insecticidal treated net (ITN) fabric comprising: a), a first zone designated as Zone-1, wherein the Zone-1 is compacted knitted pattern having weight range between 45-90 GSM; b). a second zone designated as Zone-2, wherein the Zone-2 is light compacted knitted pattern having weight range between 23-55GSM; c). a third zone designated as Zone-3, wherein the Zone-3 is light knitted having weight range between 20-50 GSM; This multi-zone uniquely knitted insecticidal treated net (ITN) fabric according to the present invention is comprising of at least two or more zones and the first zone is necessarily the Zone-1 as compactly knitted having weight range between 45-90 GSM.

[0122] GSM mentioned herein to be understood for weight in Grams per Square Meter, which refers to the weight of a fabric. In general terminology, it is to be understood that the higher a fabric's GSM, the thicker and more hard-wearing it's likely to be.

[0123] Said Zone-1 of the ITN shall have specific characteristics like - a unique knitting pattern- and possessing improved resistance to abrasion and damage since this zone shall be mostly used in the bottom part of nets as tucked in underneath the bed and subject to heavy handling. As per embodiments of the present invention, Zone-1 shall have a compactly knitted pattern produced by warp knitting mode having a weight ranging between 45-90 GSM, and it shall have a height ranging between 0-12 inches from the bottom.

[0124] The present invention embodiments provide a multi-zone uniquely knitted insecticidal treated net (ITN) fabric, wherein the insecticide treated nets (ITNs) is produced out by a warp knitting process from insecticide incorporated monofilaments extruded out of polymer matrix and have a linear density ranging between 70 to 200 denier.

[0125] The embodiments of the present invention provide multi -zone uniquely knitted insecticidal treated net (ITN) fabric; wherein multi-zone comprises of at least a light knitted fabric having a weight range between 20-50 GSM. This zone may be preferably like Zone- 2 or Zone-3 having weight ranging between 23-50 GSM or both with seamless interfaces (or without any stitching or stitch less interface between both zones). The term seamless interface is used hereinafter to define as stitch less or without any sewing process involved to integrate any of the knitted fabric zones into single fabric. Alternatively, where seamless knitting is not possible, all the zones may be sewed together individually within the scope of the present invention.

[0126] The advantage of lightweight uniquely knitted patterns by warp knitting computerized controlled consistent process is in making it more affordable and more effective

[0127] ITNs with moderate or lesser insecticidal loading / incorporation of highly expensive insecticides / pesticides (viz, Spinosad, Emamectin, Spinoteram, Milbemectin, Doramectin, Eprinomectin, Etofenprox, Ivermectin, Selamectin, Milbemycin oxime, Moxidectin, Lepimectin, Nemadectin, Bifenthrin, Chlorantraniliprole, Cyanoantraniliprole, Chlorfenapyr etc) as per the need of loading / incorporation in the well exposed areas of nets.

[0128] Among the multizone knitting patterns, according to the present invention, embodiments can also include that individual zones can have different insecticide or combinations of insecticides (AIs) incorporated into the monofilament.

[0129] In a particular embodiment according to the present invention, the seamless multizone unique knitting pattern may be derived from a combination of multiple monofilaments with each filament having a same or different insecticide or combination of insecticides to be combined to form different zones of the knitted fabric.

[0130] The multi-zone uniquely knitted insecticidal treated net (ITN) fabric according to the present invention, wherein monofilaments used in the knitting comprising with incoiporated insecticidal composition in polymer matrix and polymer matrix is selected from but not limited to polyethylene or polypropylene.

[0131] The embodiments of the present invention includes a multi -zone uni quely knitted insecticidal treated net (ITN) fabric of insecticide incorporated monofilaments, wherein monofilaments contains incorporated insecticide or combination of insecticides selected from but not limited to Bifenthrin, Permethrin, lambda-Cyhalothrin, alpha Cypermethrin or Deltamethrin or Chlorfenapyr or expensive insecticides / pesticides viz, Spinosad, Emamectin, Etofenprox, Spinoteram, Milbemectin, Doramectin, Eprinomectin, Ivermectin, Selamectin, Milbemycin oxime, Moxidectin, Lepimectin, Nemadectin, Chlorantraniliprole, Cyanoantraniliprole or other suitable insecticides.

[0132] The embodiments of the present invention also include that monofilaments incorporated with insecticide may optionally contain an organic synergist selected from Piperonyl butoxide (PBO), o-cresol derivatives or other substances acts likewise.

[0133] The embodiments of the present invention may also include that monofilaments incorporated with insecticide may also optionally contain an Insect Growth Regulator (IGR) selected from pyriproxifen, novaluron, Bistrifluron, fenoxycarb, kinoprene, methoprene, hydroprene, Tebufenozide, methoxyfenozide, halofenozide, and chromafenozide.

[0134] The term IGR may be defined here for more clarity as insect growth regulators (IGR) are a type of insecticides that mimic hormones or similar entities in young insects. They disrupt the pathway of insects growing and reproduction. IGRs can control many types of insects including fleas, cockroaches, and mosquitoes. Among the well-known categories of IGRs, there are three main classes of IGRs that are commonly used:

[0135] • Juvenile Hormone (JH) Mimics.

[0136] • Chitin Synthesis Inhibitors (CSIs)

[0137] • Dipteran Molting Disruptors.

[0138] Any class IGRs may be incorporated in the polymer matrix as an optional ingredient.

[0139] In a preferred embodiment, the multi-zone uniquely knitted insecticidal-treated net (ITN) fabric may comprise different insecticides or combinations thereof incorporated into individual zones of the fabric, depending on the intended function of each zone and the probability of contact with insect vectors.

[0140] For example, the body-contact zone (e.g., zone-2), which is more likely to be in frequent and prolonged contact with humans, may be treated with a low-volatility, slow- release insecticide having high knockdown and repellency activity with minimal skin irritation potential. In contrast, the ventilation zone (e.g., zone-3), which is more exposed to open air and vector entry points, may be treated with an insecticide that offers higher vapor action, spatial repellency, or even a combination of active agents to provide a barrier effect.

[0141] This zonal differentiation enables customized insecticidal profiles tailored to specific exposure risks, usage conditions, and vector behaviors — enhancing overall bioefficacy, resistance management, and user safety.

[0142] The strategy of differentiated insecticide loading per zone also supports resistance management programs, allowing combinations of insecticides with differing modes of action (MoA) to be spatially separated yet functionally integrated in a single net structure. The ITN fabric is insecticidally treated, either through incorporation of one or more insecticides into the polymer filaments during extrusion or by surface treatment / coating.

[0143] This multi-zone fabric construction enables the ITN to be used in a wide variety of applications beyond conventional mosquito bed nets. Specifically, the fabric may be adapted for use as: Mosquito nets and bed nets for indoor and outdoor use; it can also be used for Window and door screens allowing ventilation while providing insect protection; Tents, camping shelters, and canopies; Protective curtains in hospitals, dormitories, or public health centres; Protective clothing and accessories such as head nets, jackets, or sleeves; Outdoor or semi-permanent enclosures, including livestock pens, gazebos, or shade structures

[0144] In a further embodiment according to the present invention, it provides a seamless multi-zone uniquely knitted insecticidal treated net (ITN) fabric, wherein the insecticide treated nets (ITNs) is produced out by warp knitting from insecticide incorporated monofilament yarn extruded out of the polymer matrix and having a linear density ranging between 70 to 200 denier.

[0145] In an embodiment of the present invention, the multi-zone, uniquely knitted insecticide-treated net (ITN) fabric is used in the manufacture of insecticidal nets or protective barriers for the prevention or control of vector-borne diseases, particularly those transmitted by mosquitoes such as malaria, dengue, chikungunya, and other related diseases.

[0146] In an embodiment of the present invention, a three-zone uniquely knitted insecticidal treated net (ITN) fabric comprising: a) First zone (zone-1) is formed by unique knitting pattern having weight range between 20-50 GSM; and knitted using at least 2 ground bars. b) Second zone (zone-2) is formed by a less compacted knitting pattern having weight range between 23-55 GSM; and knitted using at least 2 ground bars. c) Third zone (zone-3) is formed by a light knitting pattern having a weight range between 20-50 GSM; and knitted using at least 2 ground bars. wherein all three zones are knitted and integrated with the seamless interface between each zone and different insecticides or combinations thereof are incorporated in each zone depending on functional requirement and vector contact probability.

[0147] In an embodiment of the present invention, provides a multi-zone uniquely knitted mosquito net comprising: a) a roof or top panel configured to allow the escape of heat and moisture from the sleeper; and b) one or more side panels integrally sewed or seamlessly knitted to the roof or top panel, wherein each side panel comprises at least two zones each having distinct knitting patterns.

[0148] In an embodiment, the said the side panel(s) comprising two or more functionally and structurally different zones namely first zone designated as zone-1, a second zone designated as zone-2, and third zone designated as zone-3.

[0149] The said zone-1 may also be referred as “Durability zone”, zone-2 as “Body contact zone” and zone-3 as “Ventilation Zone” respectively based on their function.

[0150] The said zone-1 is a bottom zone comprising compactly knitted fabric produced by warp knitting mode having a weight ranging between 45-90 GSM and height ranging between 0-45 cm from edge of the net. The said zone-1 has improved resistance to abrasion and damage since this zone is used in the bottom part of nets as tucked in underneath the bed and subject to heavy handling.

[0151] The said zone-2 is central zone which is above zone-1 and below zone-3 with a unique knitted pattern having weight range between 23-55 GSM and height ranging between 20-80 cm. This zone is a body contact zone provides soft touch feeling from the inside during use.

[0152] The said zone-3 is an upper zone between zone-2 and roof / top panel with a unique knitted pattern having weight range between 20-50 GSM and height ranging between 50-220 cm provides high ventilation temperature regulation inside the net.

[0153] In an embodiment of the present invention, wherein the said zone-1 is having a weight ranging between 20-50 GSM, the said zone-2 is having weight range between 23-55 GSM and the said zone-3 is having weight range between 20-50 GSM.

[0154] In an embodiment of the present invention, wherein the roof or top panel can be made from using monofilaments or multifilaments are extruded from a polymer matrix selected from polyethylene, polypropylene, PET, nylon, or mixtures thereof, and optionally incorporated or coated with at least one or more insecticide active ingredient(s).

[0155] In an embodiment of the present invention, wherein each of the side panels made from polymeric monofilaments, wherein each zone having distinct knitted pattern and fabric density to perform the above said characteristics.

[0156] In an embodiment of the present invention, wherein roof / top panel and zone-3 has same knitted pattern and fabric density to provide maximum ventilation and zone-2 and zone- 1 having distinct knitted pattern and fabric densities to perform the above said characteristics.

[0157] In an embodiment of the present invention, wherein roof / top panel and zone-3 has same knitted pattern and fabric density to provide maximum ventilation in the upper portion of net structure and zone-2 and zone-1 having unique knitted pattern and fabric densities in which the combination offers an extended length of continuous inner surface which provides soft touch feeling from the inside during use.

[0158] Another embodiment of the present invention, the polymer filaments used in the formation fabric net are optionally incorporated with at least one insecticidal active ingredient, useful for making insecticidal-treated Nets (ITN) more effective and long-lasting with improved user acceptance.

[0159] Among the multizone knitting patterns, according to the present invention, embodiments can also include individual zones optimally can have different insecticide or combinations of insecticides (AIs) or same insecticide / combinations thereof incorporated into the monofilament.

[0160] Another embodiment of the present invention, wherein different insecticides or combinations thereof are incorporated in each zone depending on functional requirement and vector contact probability. In a particular embodiment according to the present invention, the seamless multizone unique knitting pattern may be derived from a combination of multiple monofilaments optionally with each filament having a different insecticide or combination of insecticides thereof to be combined to form different zones of the knitted fabric.

[0161] In a particular embodiment according to the present invention, it provides a three-zone seamless uniquely knitted insecticidal treated net (ITN) fabric according to FIG. -1 and FIG- 2 comprising: a) Zone-1 is formed by compacted knitting pattern having weight range between 45- 90 GSM; and knitted using at least 2 ground bars. b) Zone-2 is formed by a less compacted knitting pattern having weight range between 23-55 GSM; and knitted using at least 2 ground bars. c) Zone-3 is formed by a light knitting pattern having a weight range between 20-50 GSM; and knitted using at least 2 ground bars.

[0162] Further, a particular embodiment provides three-zone uniquely knitted insecticidal treated net (ITN) fabric in such a way that all three zones are knitted well integrated with the seamless interface between each two zones according to FIG. 3, FIG. 6, and FIG. 9.

[0163] The unique multi-zone fabric knitting patterns of insecticidal incorporated polymer matrix of monofilaments can be useful in making ITNs that are more affordable with improved user acceptance and durability with moderate or lesser insecticidal loading / incorporation of highly expensive insecticides / pesticides (viz, Spinosad, Emamectin, Spinoteram, Milbemectin, Doramectin, Eprinomectin, Ivermectin, Selamectin, Milbemycin oxime, Moxidectin, Etofenprox, Lepimectin, Nemadectin, Bifenthrin, Chlorantraniliprole, Cyanoantraniliprole, Chlorfenapyretc) as per the need of loading / incorporation in the well- exposed zones of nets instead of zones that are not exposed to disease vectors like Zone-1 that gets tucked underneath the bed.

[0164] In a particular embodiment of the present invention, provides a rectangular shaped multi-zone uniquely knitted insecticidal treated mosquito net (ITN) according to FIG- 10, FIG-11 and FIG.-13 comprising: a) a roof or top panel configured to allow the escape of heat and moisture from sleeper; and b) four side panels integrally sewed or seamlessly knitted to the roof or top panel; wherein each side panel comprises at least two zones having distinct knitting patterns;

[0165] Wherein said the four-side panel comprises three different zones namely first zone designated as Zone-1, a second zone designated as Zone-2, and third zone designated as Zone- 3 thereof.

[0166] The said Zone-1 may also be referred as “Durability Zone”, Zone-2 as “Body contact Zone” and Zone-3 as “Ventilation Zone” respectively based on their function.

[0167] Further, embodiment of present invention, the rectangular shaped multi-zone uniquely knitted insecticidal treated mosquito net (ITN) having height range between 150-220 cm, width range between 130-190 cm, length range between 180-210 cm and a total surface area subject to variation depending on the specific height x width x length (H x W x L) configuration and GSM of each zone.

[0168] In an embodiment of the present invention, provides a multi-zone uniquely knitted insecticidal treated fabric net (ITN) knitting pattern comprising: a) zone-3 having knitting pattern comprising: the yarn ply / filament of the first guide bar (GB1) lapping movement is 1-0 / 0-1 / / , and the second guide bar (GB2) lapping movement is 0-0 / 1 -1 / 0-0 / 3-3 / 2-2 / 3-3 / / , the two bar threading mode is full threading to provide open and breathable mesh structure suitable for ventilation; b) zone-2 having knitting pattern comprising: yarn ply / filament of first guide bar (GB1) lapping movement is 1 -0 / 0-1 / / , and third guide bar (GB3) lapping movement is 1-0 / 2- 3 / / , the two bar threading mode is 1 in 1 out threading to provide a moderate density mesh with a softer texture and elasticity; and c) zone-1 having at least one knitting pattern comprising: yarn ply / filament of first guide bar (GB1) lapping movement is 1 -0 / 0- 1 / / , and third guide bar (GB3) lapping movement is 1 -0 / 2-3 / / , the two bar threading mode is full threading provide a compact mesh for improved durability, abrasion resistance with high mechanical strength.

[0169] Wherein the present invention, knitting is carried out by an automated knitting machine having multiple guide bars in this each guide bar is programmed to release and control yarn ply / filament released according to lapping movements and threading modes as described above to provide seamless multi-zone net fabric with different physical and functional characteristics.

[0170] In an embodiment of the present invention, provides a multi -zone uniquely knitted insecticidal treated fabric net (ITN) knitting pattern comprising: a) zone-3 having knitting pattern comprising: yarn ply / filament of first guide bar (GB1) lapping movement is 1 -0 / 0-1 / / , and second guide bar (GB2) lapping movement is 0-0 / 1 - 1 / 0-0 / 3-3 / 2-2 / 3-3 / / , the two bar threading mode is full threading to provide open and breathable mesh structure suitable for ventilation; b) zone-2 and zone-1 both having at least one knitting pattern comprising: yarn ply / filament of first guide bar (GB1) lapping movement is 1 -0 / 0-1 / / , and third guide bar (GB3) lapping movement 1 -0 / 2-3 / / , the two bar threading mode is 1 in 1 out threading to provide a moderate density mesh with a softer texture and elasticity.

[0171] Wherein the present invention, knitting is carried out by an automated knitting machine having multiple guide bars in this each guide bar is programmed to release and control yarn ply / filament released according to lapping movements and threading modes as described above to provide seamless multi-zone net fabric with different physical and functional characteristics.

[0172] In an embodiment of the present invention, provides at least two zone uniquely knitted insecticidal treated fabric net (ITN), knitting pattern comprising: a) Zone-1 having at least one knitting pattern comprising: the yarn ply / filament from the first guide bar (GB1) lapping movement is 1-0 / 0-1 / / , and the second guide bar (GB2) lapping movement is 0-0 / 1-1 / 0-0 / 3-3 / 2-2 / 3-3 / / , the two bar threading mode is full threading to provide open and breathable mesh structure suitable for ventilation; or yarn ply / filament of first guide bar (GB1) lapping movement is 1 -0 / 0-1 / / , second guide bar (GB2) lapping movement is 0-0 / 1 -1 / 0-0 / 2-2 / 1 -1 / 2-2 / / , and third guide bar (GB3) lapping movement is 3-3 / 2-2 / 3-3 / 0-0 / 1 -1 / 0-0, the three bar threading mode is full threading to provide mesh breathability with good mechanical strength; b) Zone-2 having at least one knitting pattern comprising: yarn ply / filament of first guide bar (GB1) lapping movement is 1 -0 / 0- 1 / / , and third guide bar (GB3) lapping movement is 1 -0 / 2-3 / / , the two bar threading mode is 1 in 1 out threading to provide softer texture and elasticity; or yarn ply / filament of first guide bar (GB1) lapping movement is 1-0 / 0- 1 / / , and fourth guide bar (GB4) lapping movement 1 -0 / 2-3 / / , the two bar threading mode is full threading to provide soft and slightly firmer fabric for enhanced user comfort and controlled fabric recovery.

[0173] Wherein the present invention, knitting is carried out by an automated knitting machine having multiple guide bars in this each guide bar is programmed to release and control yarn ply / filament released according to lapping movements and threading modes as described above to provide seamless multi-zone net fabric with different physical and functional characteristics.

[0174] In an embodiment of the present invention, provides a multi -zone uniquely knitted insecticidal treated fabric net (ITN) knitting pattern comprising: a) zone-3 having knitting pattern comprising: yarn ply or filament of first guide bar (GB 1 ) lapping movement is 1 -0 / 0-1 / / , and second guide bar (GB2) lapping movement is 0- 0 / 1 -1 / 0-0 / 3-3 / 2-2 / 3-3 / / , the two bar threading mode is full threading to provide an open, breathable mesh; b) zone-2 having knitting pattern comprising: yarn ply or filament of first guide bar (GB 1 ) lapping movement is 1 -0 / 0-1 / / , and third guide bar (GB3) lapping movement is 1-0 / 2- 3 / 1 -0 / 2-3 / 1 -0 / 4-5 / / , the two bar threading mode is 1 in 1 out threading to provide enhanced softness and elasticity. c) zone- 1 having knitting pattern comprising: yarn ply or filament of first guide bar (GB 1 ) lapping movement is 1 -0 / 0-1 / / , and third guide bar (GB3) lapping movement is 1-0 / 2- 3 / 1 -0 / 2-3 / 1 -0 / 4-5 / / , the two bar threading mode is full threading to provide a compact mesh for improved durability, abrasion resistance with high mechanical strength.

[0175] Wherein the present invention, knitting is carried out by an automated knitting machine having multiple guide bars in this each guide bar is programmed to release and control yarn ply / filament released according to lapping movements and threading modes as described above to provide seamless multi-zone net fabric with different physical and functional characteristics.

[0176] In an embodiment of the present invention, provides a multi -zone uniquely knitted insecticidal treated fabric net (ITN) knitting pattern comprising: a) zone-3 and zone-2 both having same knitting pattern comprising: yarn ply or filament of first guide bar (GB1) lapping movement is 1 -0 / 0-1 / / , second guide bar (GB2) lapping movement is 0-0 / 1-1 / 0-0 / 2-2 / 1-1 / 2-2 / / , and third guide bar (GB3) lapping movement is 3-3 / 2-2 / 3-3 / 0-0 / 1 -1 / 0-0 / / , the three bar threading mode is full threading mode to provide breathable mesh with improved mechanical strength; b) zone- 1 having knitting pattern comprising: yarn ply or filament of first guide bar (GB 1 ) lapping movement is 1 -0 / 0-1 / / , and fourth guide bar (GB4) lapping movement is 1 - 0 / 2-3 / / , the two bar threading mode is full threading to produce a soft and slightly firmer texture with controlled recovery.

[0177] Wherein the present invention, knitting is carried out by an automated knitting machine having multiple guide bars in this each guide bar is programmed to release and control yarn ply / filament released according to lapping movements and threading modes as described above to provide seamless multi-zone net fabric with different physical and functional characteristics.

[0178] The embodiments of the present invention provide further specifics of the invention summarized herein below in table- 1

[0179] TABLE- 1: The unique three zone knitting pattern of net characteristics

[0180] The knitting machine used for making unique three zone or multizone knitting patterns with variable GSM of the present invention was at the R&D center premise of VKA Polymer Pvt Limited at Karur, Tamilnadu. The knitting automated machine was from KARL MAYER RS 4 N- F model type from Karl Mayer, Textilmaschinenfabrik GmbH, BruhlstraBe 25, 63179 Obertshausen, Germany. It had a working width capacity up to 6604 mm (260 inches) with 9 needles per inch (NPI). The computerized knitting pattern (Using DELTA Design Interface) was developed using several trial runs by the inventor of the present application to achieve the intended objectives of the present invention. The set-out parameters on the machine in a particular embodiment were-

[0181] TABLE-2: Example Knitting Parameter optimized for Zones (five different knitting samples)

[0182] ITN products (unique knitted fabric or filaments) derived from incorporated insecticidal composition in polymer matrix was subjected to their bio efficacy testing for controlling disease carrying vectors as well as safety evaluations. Air Permeability Measurement

[0183] In the preferred embodiment illustrated in Fig. 13, the upper portion (zone-3) of the side panel is warp-knitted using PE monofilaments in a mesh structure referred to as the “ventilation” pattern. The air permeability of this zone was measured in accordance with DIN EN ISO 9237: 1995, using a test area of 5 cm2and a differential pressure of 200 Pa. Results are expressed in mm / s, corresponding to liters per square meter per second (L / m2s).

[0184] As shown in Fig. 12, the “ventilation” pattern of zone-3 demonstrates air permeability in the range of approximately 23,000 to 25,000 mm / s. In comparison, a similar mesh fabric constructed from PET multifilament yarns exhibits air permeability in the range of 17,000 to 18,000 mm / s under identical test conditions.

[0185] These results indicate that the PE monofilament fabric used in zone-3 provides approximately 30-35% higher air permeability than a comparable PET multifilament fabric, thereby enhancing ventilation and user comfort in high-humidity or warm environments.

[0186] Tactile Sensation Analysis (TSA)

[0187] In a preferred embodiment illustrated in Fig. 13, zone-2 of the side panel, designated as the body contact zone, is warp-knitted using monofilament yarns to form a mesh fabric with a distinct soft -touch characteristic on the inner surface. The softness of this surface was objectively evaluated using the EMTEC Tactile Sensation Analyzer (TSA), supplied by Emtec Electronic GmbH, Gorkistrasse 31, D-04347 Leipzig.

[0188] The TSA employs a proprietary sound-based analysis method to measure the tactile properties of fabric surfaces by recording the intensity (RMS) and frequency (Hz) of micro- and macro-surface variations as a blade moves over the sample. Among various parameters, TS7 valuesrepresenting surface softness at frequencies between 6000-7000 Hz are particularly relevant for ITN fabric development.

[0189] As shown in Fig. 14, the inner surface of the body contact zone (Zone-2) exhibits TS7 values in the range of 20-35 RMS, comparable to PET multifilament fabrics, and significantly lower than:

[0190] • The outer surface of the body contact zone (35-70 RMS), and

[0191] • The ventilation zone comprising PE monofilament fabric (45 - 70 RMS).

[0192] These results confirm that the inside of zone-2 provides a softer, more comfortable tactile experience compared to conventional PE monofilament surfaces.

[0193] The products appear to be promising in their activities and intended role of controlling disease carrying vectors with mosquitoes or similar insects.

[0194] 1. ITN products derived from novel incorporated insecticidal composition in polyethylene polymer matrix are observed to be enough potent and exceeding the WHO threshold criteria for ITNs specifically Blood Feeding Inhibition (BFI) of > 90% and insects Mortality of > 80%.

[0195] 2. ITN products derived from a novel incorporated insecticidal composition in a polyethylene polymer matrix were found significantly superior to existing WHO Prequalified Marketed Products, which are apparently insecticidal coated but not polymeric matrix incorporated products.

[0196] The unique seamlessly knitted multizone ITN has exceptional advantages like-improved user’s acceptance due to its soft-to-touch texture of Zone-2 and improvised ventilation in this zone. Inventors of presently invention of multizone kniting pattern conceptualized based on the long-felt need of existing conventional mosquito nets, where in the zone of tucked-in (below bed) often suffered abrasions, tear and rough exposures on the hard surfaces. The solution was provided for this zone and especially focused in the seamless knitting pattern of the present invention, wherein Zone-1 with compactly knitting paterns provide significant improvement in resistance to damage of the knited fabric, especially in the Zone-1 owing to heavy texture network, which is exposed to heavy wear and tear and thus providing longer protection to the users of the seamless uniquely knitted multizone fabric.

[0197] Zonal Differentiation of Insecticidal Treatment

[0198] In one preferred embodiment of the present invention, the multi -zone uniquely knitted insecticidal-treated net (ITN) fabric is designed with at least two or more distinct zones each differing not only in knitting patern and weight, but also in the type or combination of insecticides used. This differentiation is based on the functional role of each zone and the likelihood of vector contact or penetration through the fabric.

[0199] Example Zonal Configuration:

[0200] • Zone-2 (Body-contact zone):

[0201] • Knitting: Dense, abrasion-resistant patern (see FIG. 3)

[0202] • Weight: 30-45 GSM

[0203] • Insecticide: Permethrin (2.0% w / w) or Deltamethrin (0.4% w / w) • Characteristics: Long-lasting knockdown effect; low skin irritancy; slow- release formulation

[0204] • Zone-3 (Ventilation zone):

[0205] • Knitting: Looser, open mesh pattern (see FIG. 4)

[0206] • Weight: 20-35 GSM

[0207] • Insecticide: Transfluthrin (0.8% w / w) and / or Piperonyl butoxide (PBO) as synergist

[0208] • Characteristics: High vapor-phase activity; effective spatial repellency at vector entry points

[0209] This zonal approach allows optimization of both insecticidal performance and user comfort, while addressing vector behavior, such as increased probing activity in the ventilation zones.

[0210] Experimental Example

[0211] To evaluate the performance of insecticide differentiation across zones, the following experimental setup was used:

[0212] Fabric Samples:

[0213] 1. Sample A (Conventional Net): Uniform treatment with 0.4% deltamethrin throughout.

[0214] 2. Sample B (Zonal Treated Net): Zone-2 treated with 0.4% deltamethrin; Zone-3 treated with 0.8% transfluthrin + 1.0% PBO.

[0215] Bioassay Methodology:

[0216] • WHO cone bioassay and tunnel tests were conducted using Anopheles gambiae and Aedes aegypti mosquitoes.

[0217] • Test conditions: 27 ± 2 °C, 75 ± 10% RH.

[0218] • Knockdown (KD60) and mortality (M24) were measured after 60 minutes and 24 hours respectively. Results Summary:

[0219] Also, the present uniquely designed knitting pattern with multiple zones avoids or minimizes the use of actives / insecticides / pesticides in undesired zones, like Zone-1, which is the tuck-in-the-bed zone. This leads to the idea of developing more affordable products with expensive pesticides / insecticides with novel modes of action. Furthermore, as many changes can be made to the invention without departing from the scope of the invention, it is intended that all material contained herein be interpreted as illustrati ve of the in vention and not in a limiting sense.

[0220] Advantages of the Present Invention:

[0221] • In the multi-zone knitted insecticidal net with unique knitting pattern, the roof / top panel and Zone-3 provide maximum ventilation and heat dissipation, improving user comfort during use.

[0222] • In the multi-zone knitted insecticidal net with unique knitting patterns, the zone-2 provide soft-touch feeling to user and comfort to body for prolonged use.

[0223] • In the multi-zone knitted insecticidal net with unique knitting pattern, the zone-1 provides resistance to abrasion, repeated tucking under mattresses, and high mechanical strength will improve the product life and durability.

[0224] • This unique knitting structure provides fabric to return to its original shape after stretching or deformation, without sagging or structural collapse. • The polymeric monofilaments or multifilament used in the fabric are incorporated with insecticidal active ingredients during manufacturing provide uniform distribution, long- lasting efficacy, improved wash durability and addition protection.

[0225] • The insecticide composition may be different zone-wise, this allows the target usage of insecticide or composition only in mosquito contact zones. This makes invention economically viable and environmentally sustainable.

[0226] • Seamless knitting is novel and overcomes mechanical integration issues. Each zone is warp-knitted in a unique way.

[0227] • Zone-wise insecticide loading optimization improves efficacy and cost.

Claims

1. Claims:We Claim:

1. A multi-zone, seamless, warp-knitted insecticidal-treated net (ITN) fabric comprising at least two zones: wherein, each zone is formed of polymeric monofilaments optionally incorporated with at least one insecticidal composition; each zone has a knitting pattern or fabric density that differs from at least one other zone; and wherein, the zones are seamlessly integrated with one another during the knitting process; and at least one of the zones has a fabric weight in the range of 20 to 90 (GSM).

2. The multi-zone ITN fabric according to claim- 1, comprises at least two distinct zones, wherein the first zone is configured with a body-contact knitting pattern and having a fabric weight in the range of 23 to 55 GSM; and the second zone is configured with a lighter ventilation knitting pattern and has a fabric weight in the range of 20 to 50 GSM.

3. The multi-zone ITN fabric according to claim- 1, comprises three zones, wherein the first zone is configured with a light knitting pattern having a weight range between 20- 50 GSM; and the second zone having a unique knitting pattern with inside soft feel with a weight range between 23-55 GSM; and the third zone is configured with a lighter ventilation knitting pattern with a fabric weight in the range of 20-50 GSM.

4. The multi-zone ITN fabric according to any of the preceding claims, wherein the monofilaments or multifilament are extruded from a polymer matrix selected from polyethylene, polypropylene, PET, nylon, or mixtures thereof, and optionally incorporated or coated with at least one or more insecticide active ingredient(s).

5. The multi-zone ITN fabric according to claim- 1, wherein the net fabric is produced by warp knitting from monofilament yarns which is optionally incorporated with insecticide yarn extruded out of polymer matrix and having a linear density ranging between 70 to 200 denier.

6. The multi-zone ITN fabric according to any preceding claims, wherein different insecticides or combinations thereof are incorporated in each zone depending on functional requirement and vector contact probability.

7. The multi-zone ITN fabric according to any preceding claims, wherein the ITN fabric is adapted to use as an insecticidal barrier in a variety of applications including, but not limited to, mosquito nets, bed nets, window and door screens, tents, curtains, canopies, protective clothing, and outdoor enclosures.

8. A multi-zone uniquely knitted mosquito net comprising: a) a roof or top panel configured to allow the escape of heat and moisture from the sleeper; and b) one or more side panels integrally sewed or seamlessly knitted to the roof or top panel; wherein each side panel comprises at least two zones having distinct knitting patterns.

9. The multi-zone mosquito net according to claim-8, wherein the said the side panel(s) comprising two or more functionally and structurally different zones namely first zone designated as zone-1 comprises the lower 0-45 cm, designed for abrasion resistance; second zone designated as zone-2 comprises 20-80 cm height for soft-touch user contact; and third zone designated as zone-3 comprises the upper 50-220 cm for ventilation.

10. The multi-zone mosquito net according to claim-8, wherein the said zone-1 is a bottom zone comprising compactly knitted fabric produced by warp knitting mode having a weight ranging between 45-90 GSM; said zone-2 is central zone which is above zone-1 and below zone-3 with a unique knitted pattern having weight range between 23-55 GSM and said zone-3 is an upper zone between zone-2 and roof / top panel with a unique knitted pattern having weight range between 20-50 GSM.

11. The multi-zone mosquito net according to claim-8, wherein the said zone-1 is having a weight ranging between 20-50 GSM, the said zone-2 is having weight range between 23-55 GSM and the said zone-3 is having weight range between 20-50 GSM.

12. The multi-zone mosquito net according to claim-8, wherein the mosquito net having height range between 150-220 cm, width range between 130-190 cm, length range between 180-210 cm and a total surface area subject to variation depending on the specific height x width x length (H x W x L) configuration and GSM of each zone.

13. The multi-zone mosquito net according to claim-8, wherein the roof or top panel can be made from polymeric monofilaments or multifilament are extruded from a polymer matrix selected from polyethylene, polypropylene, PET, nylon, or mixtures thereof, and optionally incorporated or coated with at least one or more insecticide active ingredient(s).

14. The multi-zone mosquito net according to any preceding claims, wherein different insecticides or combinations thereof are incorporated in each zone depending on functional requirement and vector contact probability.

15. A three-zone uniquely knitted insecticidal treated net (ITN) fabric comprising: a) First zone (zone-1) is formed by unique knitting pattern having weight range between 20-50 GSM; and knitted using at least 2 ground bars. b) Second zone (zone-2) is formed by a less compacted knitting pattern having weight range between 23-55 GSM; and knitted using at least 2 ground bars. c) Third zone (zone-3) is formed by a light knitting pattern having a weight range between 20-50 GSM; and knitted using at least 2 ground bars.

16. The three-zone uniquely knitted insecticidal treated net (ITN) fabric, according to claim- 15, wherein all three zones are knitted and integrated with the seamless interface between each zone.

17. The multi-zone uniquely knitted fabric net according to any preceding claims, wherein different insecticides or combinations thereof are incorporated in each zone depending on functional requirement and vector contact probability.

18. A multi-zone uniquely knitted insecticidal treated net (ITN) fabric comprising: a) a first zone designated as zone-1, wherein the Zone-1 is compacted knitted pattern having weight range between 45-90 GSM; b) a second zone designated as zone-2, wherein the Zone-2 is light compacted knitted pattern having weight range between 23-55 GSM; c) a third zone designated as zone-3, wherein the Zone-3 is light knitted having weight range between 20-50 GSM;19. A multi-zone uniquely knitted insecticidal treated fabric net (ITN) knitting patterncomprising: a) zone-3 having knitting pattern comprising: yarn ply or filament of first guide bar (GB 1 ) lapping movement is 1 -0 / 0-1 / / , and the second guide bar (GB2) lapping movement is 0-0 / 1-1 / 0-0 / 3-3 / 2-2 / 3-3 / / , the two bar threading mode is full threading to provide open and breathable mesh structure suitable for ventilation; b) zone-2 having knitting pattern comprising: yarn ply or filament of first guide bar (GB 1 ) lapping movement is 1 -0 / 0-1 / / , and third guide bar (GB3) lapping movement is 1-0 / 2- 3 / / , the two bar threading mode is 1 in 1 out threading to provide a moderate density mesh with a softer texture and elasticity; and c) zone- 1 having knitting pattern comprising: yarn ply or filament of first guide bar (GB 1 ) lapping movement is 1 -0 / 0-1 / / , and third guide bar (GB3) lapping movement is 1-0 / 2- 3 / / , the two bar threading mode is full threading to provide a compact mesh for improved durability, abrasion resistance with high mechanical strength.

20. A multi-zone uniquely knitted insecticidal treated fabric net (ITN) knitting pattern comprising: a) zone-3 having knitting pattern comprising: yarn ply or filament of first guide bar (GB 1 ) lapping movement is 1 -0 / 0-1 / / , and second guide bar (GB2) lapping movement is 0-0 / 1 - 1 / 0-0 / 3-3 / 2-2 / 3-3 / / , the two bar threading mode is full threading to provide open and breathable mesh structure suitable for ventilation; b) zone-2 and zone-1 both having same knitting pattern comprising: yarn ply or filament of first guide bar (GB1) lapping movement is 1-0 / 0-1 / / , and third guide bar (GB3) lapping movement 1 -0 / 2-3 / / , the two bar threading mode is 1 in 1 out threading to provide a moderate density mesh with a softer texture and elasticity.

21. A multi-zone uniquely knitted insecticidal treated fabric net (ITN) knitting pattern comprising: a) zone-3 having knitting pattern comprising: yarn ply or filament of first guide bar (GB 1 ) lapping movement is 1 -0 / 0-1 / / , and second guide bar (GB2) lapping movement is 0- 0 / 1 -1 / 0-0 / 3-3 / 2-2 / 3-3 / / , the two bar threading mode is full threading to provide an open, breathable mesh; b) zone-2 having knitting pattern comprising: yarn ply or filament of first guide bar (GB 1 ) lapping movement is 1 -0 / 0-1 / / , and third guide bar (GB3) lapping movement is 1-0 / 2-3 / 1 -0 / 2-3 / 1 -0 / 4-5 / / , the two bar threading mode is 1 in 1 out threading to provide enhanced softness and elasticity. c) zone- 1 having knitting pattern comprising: yarn ply or filament of first guide bar (GB 1 ) lapping movement is 1 -0 / 0-1 / / , and third guide bar (GB3) lapping movement is 1-0 / 2- 3 / 1 -0 / 2-3 / 1 -0 / 4-5 / / , the two bar threading mode is full threading to provide a compact mesh for improved durability, abrasion resistance with high mechanical strength.

22. A multi-zone uniquely knitted insecticidal treated fabric net (ITN) knitting pattern comprising: a) zone-3 and zone-2 both having same knitting pattern comprising: yarn ply or filament of first guide bar (GB1) lapping movement is 1 -0 / 0-1 / / , second guide bar (GB2) lapping movement is 0-0 / 1-1 / 0-0 / 2-2 / 1 -1 / 2-2 / / , and third guide bar (GB3) lapping movement is 3-3 / 2-2 / 3-3 / 0-0 / 1 -1 / 0-0 / / , the three bar threading mode is full threading mode to provide breathable mesh with improved mechanical strength; b) zone- 1 having knitting pattern comprising: yarn ply or filament of first guide bar (GB 1 ) lapping movement is 1-0 / 0-1 / / , and fourth guide bar (GB4) lapping movement is 1-0 / 2-3 / / , the two bar threading mode is full threading to produce a soft and slightly firmer texture with

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