WO2018144504A1 - Tissus de séparation et procédés de fabrication de tels tissus de séparation - Google Patents

Tissus de séparation et procédés de fabrication de tels tissus de séparation Download PDF

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Publication number
WO2018144504A1
WO2018144504A1 PCT/US2018/016081 US2018016081W WO2018144504A1 WO 2018144504 A1 WO2018144504 A1 WO 2018144504A1 US 2018016081 W US2018016081 W US 2018016081W WO 2018144504 A1 WO2018144504 A1 WO 2018144504A1
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WO
WIPO (PCT)
Prior art keywords
yarn
fabric
knit structure
zones
heating
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2018/016081
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English (en)
Inventor
Juan ARISTIZABAL
Jeffrey W. Bruner
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Knitmasters LLC
Original Assignee
Knitmasters LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Knitmasters LLC filed Critical Knitmasters LLC
Priority to US16/482,607 priority Critical patent/US20200002855A1/en
Priority to EP18747357.4A priority patent/EP3577264A4/fr
Publication of WO2018144504A1 publication Critical patent/WO2018144504A1/fr
Anticipated expiration legal-status Critical
Priority to US18/450,555 priority patent/US20230392306A1/en
Ceased legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B1/10—Patterned fabrics or articles
    • D04B1/12—Patterned fabrics or articles characterised by thread material
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B1/22—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes specially adapted for knitting goods of particular configuration
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/04—Heat-responsive characteristics
    • D10B2401/041—Heat-responsive characteristics thermoplastic; thermosetting
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2403/00—Details of fabric structure established in the fabric forming process
    • D10B2403/02—Cross-sectional features
    • D10B2403/023—Fabric with at least two, predominantly unlinked, knitted or woven plies interlaced with each other at spaced locations or linked to a common internal co-extensive yarn system
    • D10B2403/0231—Fabric with at least two, predominantly unlinked, knitted or woven plies interlaced with each other at spaced locations or linked to a common internal co-extensive yarn system including contracting yarn, e.g. blister fabrics
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2501/00—Wearing apparel
    • D10B2501/04—Outerwear; Protective garments
    • D10B2501/043—Footwear
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00—Industrial
    • D10B2505/08—Upholstery, mattresses
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00—Industrial
    • D10B2505/12—Vehicles

Definitions

  • This invention relates to spacer fabrics and, in particular, to knitted spacer fabrics and methods of making the same.
  • Spacer fabrics have been used as components of various products, ranging from footwear to costumes to backpacks.
  • two separate fabrics (which may be referred to as a top fabric and a bottom fabric) are joined by fibers or filaments in a "sandwich" like construction, in which the top fabric and bottom fabric are spaced apart from one another by the intervening fibers or filaments.
  • the intervening fibers or filaments typically have a low density, such that the region or space between the top fabric and the bottom fabric consists largely of air or empty space.
  • some prior spacer fabric constructions provide a limited resistance to compression and/or provide only a single compressive resistance throughout the fabric.
  • Some spacer fabrics can also require expensive, complicated, or time- consuming manufacturing process. Therefore, there exists a need for improved spacer fabrics and improved methods of making spacer fabrics, including for applications requiring an increased compressive resistance and/or a varying compressive resistance.
  • Spacer fabrics and methods of making the same are described herein. Such fabrics can provide one or more advantages compared to other fabrics. For example, in some instances, the spacer fabrics described herein provide improved compression resistance, strength, durability, and/or cushioning. Spacer fabrics described herein can also provide non-uniform or varying properties across one or more lateral dimensions of the fabric. For instance, in some embodiments, a spacer fabric described herein comprises a plurality of zones of differing compression resistances. Such zones can correspond to a pressure map of the spacer fabric during use in an end application, such as a seating application or a footwear application.
  • spacer fabrics described herein incorporate electrically and/or thermally conductive fibers, yarns, or filaments for providing fabrics that can be heated or cooled, perform diagnostics, and/or massage portions of a user's body during use. Additionally, methods described herein can provide or form a spacer fabric in a more efficient and/or cost- effective manner compared to some other methods.
  • a method of making a spacer fabric comprises knitting a first yarn, filament, or fiber and a second yarn, filament or fiber to form a knit structure, wherein the knit structure comprises a plurality of concave portions in facing opposition to a plurality of convex portions.
  • the concave portions and the convex portions define void spaces having a substantially double convex cross section.
  • the first yarn, filament, or fiber is a low thermal shrinkage yarn, filament, or fiber
  • the second yarn is a high thermal shrinkage yarn, filament, or fiber, where "low” and "high” are understood to be relative terms, as described further hereinbelow.
  • the method further comprises heating the knit structure at a temperature sufficient to cause the second yarn (or filament or fiber) to shrink by at least 10% in at least one dimension.
  • the second yarn (or filament or fiber) shrinks more than the first yarn (or filament or fiber) in the at least one dimension during the step of heating the knit structure.
  • the second yarn (or filament or fiber) shrinks by 10-90%) in the at least one dimension during the step of heating the knit structure, based on an original size of the second yarn (or filament or fiber) in the at least one dimension prior to the step of heating the knit structure.
  • the second yarn (or filament or fiber) shrinks at least two times as much as the first yarn (or filament or fiber) in the at least one dimension during the step of heating the knit structure.
  • the step of heating the knit structure can increase a size of the void spaces in a thickness direction of the fabric.
  • the step of heating the knit structure increases the size of the void spaces in the thickness direction of the fabric by at least 100%.
  • a method described herein can further comprise forming a knit structure from one or more additional yarns, in addition to the first yarn and the second yarn.
  • additional yarns may be used to form a knit structure described herein, wherein n is not particularly limited (e.g., n can be equal to 1, 2, 3, 4, or 5, or n can be equal to any integer between 1 and 100).
  • a method described herein further comprises forming a knit structure from a third (or nth) yarn in addition to the first yarn and the second yarn (or in addition to the previously recited (n-1) yarns).
  • the third yarn (or nth yarn) can differ from the first yarn and the second yarn (or from one or more of the (n-1) previously recited yarns).
  • the third yarn (or nth yarn) is a thermally fusible yarn.
  • the third yarn (or nth yarn) can be fusible at the temperature of the step of heating the knit structure.
  • a method described herein can further comprise forming a knit structure from a fourth yarn in addition to the first yarn, the second yarn, and the third yarn.
  • the fourth yarn can differ from the first yarn, the second yarn, and the third yarn.
  • the fourth yarn can have a color, texture, denier, and/or elasticity that differs from the color, texture, denier, and/or elasticity of the first yarn, the second, yarn, and/or the third yarn. It is again to be understood that methods described herein are not limited to the use of 3 or 4 differing yarns. Instead, n yarns or yarn types may generally be used, and the n yarns or yarn types may be the same or different from one another in a variety of ways, including those described above.
  • a spacer fabric described herein, after heating can comprise a plurality of zones having differing properties.
  • the spacer fabric, after heating has or exhibits different compression resistances in a thickness direction of the fabric (where the thickness direction may be denoted as the z-direction).
  • the compression resistance of the fabric varies as a function of one or both lateral dimensions of the fabric (where the lateral dimensions or directions of the fabric may be denoted as the x-direction and the y-direction).
  • a spacer fabric formed by a method described herein can have one or more first zones of low compression resistance and one or more second zones of high compression resistance, where the terms "low” and "high” are understood to be relative to one another.
  • the first zones in some embodiments, have a compression resistance of no more than 30 psi
  • the second zones have a compression resistance of at least 50 psi.
  • the locations of the first and second zones can be determined based on a pressure map of the fabric when in use in an end application.
  • the end application can be a seating application, a footwear application, or any other application not inconsistent with the objectives of the present disclosure.
  • a spacer fabric described herein comprises a knit structure formed from a first yarn and a second yarn, wherein the knit structure comprises a plurality of concave portions in facing opposition to a plurality of convex portions, the concave portions and the convex portions defining void spaces.
  • the void spaces can have double convex or substantially double convex cross sections.
  • the first yarn can comprise a low thermal shrinkage yarn and the second yarn can comprise a high thermal shrinkage yarn.
  • the terms "low” and "high” are to be understood to be relative to one another.
  • the second yarn shrinks at least twice as much as the first yarn in at least one dimension at a heat shrinking temperature between 50°C and 150°C.
  • heating the knit structure at a temperature sufficient to cause shrinkage of the second yarn by at least 10% in at least one dimension will increase a size of the void spaces in a thickness direction of the fabric.
  • a spacer fabric described herein when unheated, is flat or substantially flat.
  • a thickness of the fabric increases by at least 0.5 cm when the fabric is heated at a temperature sufficient to cause shrinkage of the second yarn by at least 10% in at least one dimension.
  • knit structures described herein can be formed from one or more yarns in addition to the first and second yarns. Up to "n" additional yarns may be included in a knit structure descried herein.
  • a knit structure is formed from a third yarn in addition to the first yarn and the second yarn, and the third yarn differs from the first yarn and/or the second yarn.
  • the third yarn comprises a thermally fusible yarn.
  • the third yarn may be fusible at a temperature sufficient to cause the second yarn to shrink by at least 10% in at least one dimension.
  • a knit structure of a fabric described herein may be formed from a fourth yarn in addition to the first yarn, the second yarn, and the third yarn.
  • a fourth yarn can differ the first yarn, the second yarn, and/or the third yarn.
  • the fourth yarn can have a color, texture, denier, and/or elasticity that differs from the color, texture, denier, and/or elasticity of any of the first yarn, the second, yarn, and/or the third yarn.
  • the knit structure of a fabric described herein in certain embodiments, is a unitary knit structure.
  • a fabric described herein comprises a plurality of zones having different compression resistances in a thickness direction of the fabric.
  • the fabric can comprise one or more first zones of low compression resistance and one or more second zones of high compression resistance.
  • the first zones can have a compression resistance of no more than 30 psi and the second zones can have a compression resistance of at least 50 psi.
  • the locations of the first and second zones can correspond to a pressure map of the fabric when in use in an end application.
  • the fabric forms a portion of a seat or seat back.
  • the fabric can form a portion of footwear.
  • FIG. 1A illustrates a perspective view of a spacer fabric according to one embodiment described herein.
  • FIG. IB illustrates a perspective view of a spacer fabric according to one embodiment described herein.
  • FIG. 1C illustrates a perspective view of a spacer fabric according to one embodiment described herein.
  • FIG. 2 schematically illustrates a sectional view of a spacer fabric before and after carrying out a heating step according to one embodiment described herein.
  • FIG. 3 illustrates a perspective view of a spacer fabric before carrying out a heating step according to one embodiment described herein.
  • FIG. 4 illustrates a perspective view of the spacer fabric of FIG. 3 after carrying out a heating step according to one embodiment described herein.
  • FIG. 5 schematically illustrates a sectional view of a conventional weft knitted spacer fabric for comparison purposes.
  • FIG. 6 illustrates a perspective view of a conventional spacer fabric corresponding to the spacer fabric of FIG. 5.
  • FIG. 7 is a needle diagram illustrating a method of knitting a spacer fabric according to one embodiment described herein.
  • FIG. 8 is a needle diagram illustrating a method of knitting a spacer fabric according to one embodiment described herein.
  • FIG. 9A is a needle diagram illustrating a method of knitting a spacer fabric according to one embodiment described herein.
  • FIG. 9B is a needle diagram illustrating a method of knitting a spacer fabric according to one embodiment described herein.
  • FIG. 9C is a needle diagram illustrating a method of knitting a spacer fabric according to one embodiment described herein.
  • FIG. 9D is a needle diagram illustrating a method of knitting a spacer fabric according to one embodiment described herein.
  • FIG. 9E is a needle diagram illustrating a method of knitting a spacer fabric according to one embodiment described herein.
  • FIG. 9F is a needle diagram illustrating a method of knitting a spacer fabric according to one embodiment described herein.
  • a method described herein can provide a spacer fabric that has improved compression resistance.
  • a method described herein can also be used to make a spacer fabric having a plurality of zones of differing compression resistances.
  • the zones can correspond to a pressure map of the spacer fabric during use in an end application, such as a seating application or a footwear application.
  • a method described herein can provide a spacer fabric in a more efficient and/or cost-effective manner compared to some other methods.
  • a method of making a spacer fabric described herein comprises knitting a first yarn (or fiber) and a second yarn (or fiber) to form a knit structure, wherein the knit structure comprises a plurality of concave portions in facing opposition to a plurality of convex portions.
  • the concave portions can be repeating portions, such that they form a wave-like or sinusoidal shape in a length or width direction of the knit structure.
  • the convex portions can be repeating portions, such that they form a wave-like or sinusoidal shape in a length or width direction of the knit structure, as described further below.
  • the concave portions and the convex portions together define void spaces having a substantially double convex cross section. More particularly, the concave portions and the convex portions can be aligned with one another, including in a one-to-one manner, such as may be caused by an off-set in the sinusoidal shape or pattern formed by the plurality of concave portions and the sinusoidal shape or pattern formed by the plurality of convex portions.
  • each concave portion is mirrored by or aligned with a corresponding convex portion in facing opposition to the concave portion, thereby defining a double convex void space.
  • a "double convex" cross section or shape is a shape defined by two convex curves in a back to back configuration, such as in a double convex lens, as opposed to the configuration of a plano-convex lens or a concavo-convex lens.
  • substantially double convex cross section or shape refers to a cross section or shape that is essentially a double convex cross section or shape, but that may differ from such a shape by a de minimis amount, such as by having an "offset" from a back to back configuration of less than 5%, less than 3%, or less than 1%.
  • the knit structure of a spacer fabric described herein can be a unitary knit structure, as opposed to a knit structure formed by sewing, linking, or otherwise joining separate fabrics in a non -knitting manner.
  • the first yarn (or fiber) used to form the knit structure is a low thermal shrinkage yarn (or fiber)
  • the second yarn (or fiber) is a high thermal shrinkage yarn (or fiber).
  • the terms “low” and “high” thermal shrinkage are relative to one another. In other words, the "low” thermal shrinkage yarn shrinks less in response to heating than the "high” thermal shrinkage yarn does.
  • the "high" thermal shrinkage yarn (or fiber) shrinks at least twice as much, at least three times as much, at least five times as much, or at least 10 times as much as the "low” thermal shrinkage yarn (or fiber) at a given temperature or other heating condition, in at least one dimension, where the amount of shrinkage of each yarn (or fiber) is a percent shrinkage based on the original dimension of the respective yarn (or fiber) at 25°C, prior to heating.
  • the high thermal shrinkage yarn (or fiber) shrinks 2-100 times, 2-50 times, 2-20 times, 2-10 times, 2-5 times, 2-4 times, 5- 100 times, 5-50 times, 5-20 times, 5-10 times, 10-100 times, 10-50 times, or 10-20 times as much in at least one dimension as the low thermal shrinkage yarn (or fiber) does at a given temperature or other heating condition.
  • the dimension of thermal shrinkage is a longitudinal or "length" direction of the yarn (or fiber), as opposed to a radial or "width" dimension of the yarn (or fiber).
  • thermal shrinkage occurs in a radial direction of a yarn (or fiber).
  • differential thermal shrinkage occurs in a radial direction as well as a longitudinal direction of the yarns (or fibers).
  • methods described herein further comprise heating the knit structure at a temperature sufficient to cause the second yarn or fiber to shrink in at least one dimension.
  • the second yarn or fiber shrinks by at least 10% in at least one dimension, where the percentage is based on an original size or length of the second yarn or fiber in the at least one dimension prior to the step of heating the knit structure.
  • the second yarn or fiber shrinks by at least 20%, at least 30%, or at least 40% in at least one dimension.
  • the second yarn or fiber shrinks by 10-90%) in the at least one dimension during the step of heating the knit structure.
  • the second yarn or fiber shrinks more than the first yarn or fiber in the at least one dimension during the step of heating the knit structure.
  • the first yarn or fiber shrinks by less than 10%>, less than 8%>, less than 5%), or less than 3%> in the at least one dimension during the heating step, based on an original size or length of the first yarn or fiber in the at least one dimension prior to the step of heating the knit structure.
  • the step of heating the knit structure increases a size of the void spaces of the knit structure, particularly in a thickness direction or z-direction of the fabric.
  • a "thickness" direction of the fabric is orthogonal to the width and length directions (or x- and y-directions) of the fabric.
  • the "thickness" or z-direction is the shortest dimension of the fabric, which may have much larger width (x-) and length (y-) directions.
  • the z-direction of the fabric can be generally orthogonal to the "direction of propagation" or "crest-to-crest direction" of the sinusoidal shapes or patterns formed by the plurality of concave portions and the plurality of convex portions.
  • the step of heating the knit structure increases the size of the void spaces in the thickness direction of the fabric by at least 100%>. In some cases, the step of heating the knit structure increases the size of the void spaces in the thickness direction of the fabric by at least 200%, at least 300%, at least 400%, at least 500%, at least 700%, at least 900%, or at least 1000%).
  • the size of the void spaces in the thickness direction of the fabric increases by 100-5000%, 100-1000%, 100-900%, 100-500%, 100-300%, 200-5000%, 200- 1000%, 300-5000%, or 300-1000%. Additionally, in some embodiments, the fabric is flat or substantially flat prior to heating, and raised or non-flat or "three-dimensional" after heating. In some instances, the thickness of the fabric increases by at least 0.5 cm, at least 1 cm, at least 2 cm, at least 3 cm, or at least 5 cm after heating. Other increases in thickness are also possible.
  • a “substantially” flat fabric for reference purposes herein, can be within 10%>, within 5%, within 3%), or within 1%> of being flat under standard temperature and pressure conditions (in particular IUPAC STP conditions), the percentage being based on an increase in thickness of the
  • a knit structure is formed from a single component yarn, a multi-component yarn (such as a bi-component yarn or a yarn having 3 components (i.e., a tri-component yarn), a yarn having 4 components (i.e., a quad-component yarn), or a yarn having more than 4 components), or a combination thereof.
  • a multi-component yarn can have a sheath/core structure, a side-by-side structure, or an islands-in-the-sea structure. Other multi- component yarn structures can also be used.
  • a knit structure is formed from a mono-component monofilament yarn, a multi-component monofilament yarn, a mono-component multifilament yarn, a multi-component multifilament yarn, or a combination thereof.
  • a yarn used in a method described herein may also include separate filaments formed from different materials, or a plurality of filaments that are each formed from two or more different materials. It is also to be understood that a “yarn” such as a "first yarn” or a "second yarn” described herein can refer to a type of yarn, as opposed to simply a single yarn.
  • first yarn and second yarn to provide a knit structure in a manner described herein is to be understood to refer to the use of one or more yarns of a first type (corresponding to "a first yarn”) and one or more yarns of a second type (corresponding to "a second yarn”).
  • the first yarn is a monofilament yarn.
  • the first yarn is a monocomponent monofilament yarn or a multi- component monofilament yarn.
  • the first yarn has a higher stiffness or modulus than the second yarn.
  • the second yarn is a multifilament yarn.
  • the second yarn is a monocomponent multifilament yarn or a multi-component multifilament yarn.
  • a knit structure described herein is formed from a third yarn in addition to the first yarn and the second yarn, the third yarn differing from the first yarn and the second yarn.
  • Any third yarn not inconsistent with the objectives of the present disclosure can be used.
  • the third yarn is a thermally fusible or heat-fusible yarn. In some cases, such a third yarn is fusible at the temperature of the step of heating the knit structure. Additionally, in some such instances, stable and elastic single component multifilament and/or monofilament yarns are used as the third yarns.
  • the yarns can be formed from low melting point polymers, such as polymers having a melting point below about 200°C, 150°C, below about 100°C, or below about 80°C. In some embodiments, the yarns can be formed from polymers having a melting point between about 80°C and about 150°C. Such yarns can be heated, with or without pressure, to cause the low melting components to melt and flow, thereby modifying the physical properties of the knit structure, including by serving as an adhesive. In other cases, stable and elastic multi-component (e.g., bi-component)
  • the yarns can be formed from low melting polymers in combination with higher melting point polymers (such as polyester or nylon), such that the low melting polymer components but not the higher melting components of the yarns can be made to melt and flow by the application of heat with or without pressure, thereby modifying the physical properties of the knit structure in a desired manner, including by providing an adhesive element and/or structural support.
  • higher melting point polymers such as polyester or nylon
  • a knit structure described herein is formed from a fourth yarn in addition to the first yarn, the second yarn, and the third yarn, wherein the fourth yarn differs from the first yarn, the second yarn, and the third yarn.
  • Any fourth yarn not inconsistent with the objectives of the present invention can be used.
  • the fourth yarn can be used to provide desired performance features to a spacer fabric described herein, in addition to those described above.
  • the fourth yarn has a color, texture, denier, and/or elasticity that differs from a color, texture, denier, and/or elasticity of the first yarn, the second, yarn, and/or the third yarn.
  • a fiber, yarn, or filament or a portion of a fiber, yarn, or filament described here can comprise or be formed from any material not inconsistent with the objectives of the present invention.
  • a fiber, yarn, or filament comprises or is formed from a synthetic material such as nylon or another polyamide, polyester, polyethylene, polypropylene, polybutylene, or another polyolefin, or polyacrylic.
  • a fiber, yarn, or filament comprises or is formed from a natural fiber material such as cotton, wool, or silk.
  • Other fibers, yarns, and filament materials may also be used, such as regenerated cellulose or rayon.
  • the fiber, yarn, or filament comprises or is formed from a rate-sensitive material, such as a rate-sensitive thermoplastic elastomer.
  • a rate-sensitive material such as a rate-sensitive thermoplastic elastomer.
  • Such materials are configured to exhibit different stiffness values at different frequencies or rates.
  • rate-sensitive materials can be soft, comfortable, and flexible at lower frequencies, but stiffen under higher frequencies for increasing the stability and performance.
  • An exemplary rate- sensitive material is D30 ® , a DuPontTM Hytrel® thermoplastic elastomer.
  • the fiber, yarn, or filament comprises or is formed from a metallic material such as stainless steel, copper, or a metal mixture or metal alloy.
  • the metallic material is electrically conductive.
  • Other electrically conductive fibers, yarns, or filaments may also be used.
  • Such electrically conductive materials can be used, in some cases, for the dissipation of static charge and/or for the formation of "smart" or electrically integrated materials.
  • formation of a smart material enables a spacer fabric constricted therefrom to provide diagnostics.
  • diagnostics may include, for example, and without limitation, step-counting diagnostics, speed diagnostics, force or impact diagnostics, or any other type of diagnostic not inconsistent with objectives of the present invention.
  • a fiber, yarn, or filament described herein may include or be formed from a shape memory material such as a shape memory polymer or a shape memory alloy.
  • Other materials, such as pressure-chromic yarns may be used in the methods of forming the spacer fabrics described herein, for example, so that the spacer fabric is responsive or reactive to various changes or stimuli and, thus, varies in regards to the amount of stiffness or pressure provided by the fabric.
  • Such fabrics may be used, for example, to massage the user's body (e.g., back, foot, etc.) when positioned adjacent or proximate to the spacer fabric.
  • a fiber, yarn, or filament described herein can also be coated with one or more additional materials to provide a desired property.
  • a fiber, yarn, or filament can be coated with a fluorocarbon such as polytetrafluoroethylene.
  • a fiber, yarn, or filament described herein can also include one or more additives, including polymer additives, which can provide heat absorption and/or heat reflectivity properties, electrical conductivity and/or static dissipation properties, or low coefficient of friction properties.
  • additives may be used to heat or cool the spacer fabric during use, such that the user's body (e.g., back, foot, etc.) may be heated or cooled during use via the spacer fabric.
  • An additive can also be used to provide a "smart" fabric or textile.
  • thermally conductive additives which may be used in some embodiments described herein include ceramics such as aluminum nitride and/or boron nitride ceramics, metals such as aluminum or copper, and nanoscale carbon materials such as carbon fibers, carbon nanotubes, and graphite nanoplatelets.
  • Additives comprising thermochromic or photochromic pigment and dye materials may also be used. Such pigment and dye materials can change color in response to heat or light. It is also possible to incorporate one or more antimicrobial or antifungal materials into or onto a fiber, yarn, or filament described herein, including for odor control.
  • Non-limiting examples of antimicrobial or antifungal materials that may be used in some embodiments described herein include inorganic, organic, and/or metal -containing antimicrobial materials such as materials comprising silver, copper, and/or zinc, and quaternary silane-based antimicrobial materials.
  • a fiber, yarn, or filament described herein can have any size, shape, and/or denier not inconsistent with the objectives of the present invention.
  • a spacer fabric formed by a method described herein can comprise regions having the same or differing properties.
  • a spacer fabric can have regions of the same or differing stability, rigidity, elasticity, support, softness, cover, durability against fraying, durability against unraveling, cushioning, compression, breathability, weight, density, color, water wicking ability, and/or water resistance.
  • the properties of a region of a spacer fabric described herein can be selected based on the type of knitting process, the type of stitch, and/or the chemical composition or type of fiber, yarn, or filament used to form the region.
  • a spacer fabric can be provided that has both a unitary knitted structure and also complex features, varied regions, or features or regions selected for specific applications.
  • the unitary structure can be formed by a single knitting operation according to a method described herein.
  • a spacer fabric made by a method described herein can have one or more regions of high breathability (such as may be provided by the use of a meshed stitch structure), one or more regions of high elasticity (such as may be provided by the use of an elastomeric yarn), one or more regions of high rigidity (such as may be provided by the use of a non- elastomeric yarn), and/or one or more regions that can be further shaped using the heat treatment (such as may be provided by the use of a fusible yarn).
  • a spacer fabric made by a method described herein can include relatively soft regions and relatively abrasion resistant regions.
  • a soft region may be located on one side (e.g., a user contacting side) of the spacer fabric, and an abrasion resistant region may be located on the other side (e.g., a non-user contacting side) of the spacer fabric.
  • Selectively varying the type of knitting process, the type of stitch, and/or the chemical composition or type of fiber, yarn, or filament used during a method described herein can also provide spacer fabric having desired aesthetic, design, or texture elements.
  • a spacer fabric described herein after heating, comprises a plurality of zones having different compression resistances in a thickness direction of the fabric.
  • the spacer fabric has one or more first zones of low compression resistance and one or more second zones of high compression resistance.
  • “low” and “high” compression resistance are relative to one another.
  • the first zones have a compression resistance of no more than 30 psi, no more than 20 psi, or no more than 10 psi
  • the second zones have a compression resistance of at least 50 psi, at least 60 psi, at least 70 psi, at least 80 psi, or at least 100 psi.
  • the locations of the first and second zones are determined based on a pressure map of the fabric when in use in an end application.
  • Spacer fabrics described herein can be used in any end application not inconsistent with the objectives of the present disclosure. Moreover, spacer fabrics described herein can be formed in a custom manner to meet the needs of a specific end use. Additionally, in general, a knit structure/spacer fabric described herein can have a definitive custom shape and dimension around the perimeter of the end product (e.g., the final fabric to be used in an end application) that is shaped on the knitting machine for the end use. In other words, the spacer fabric can be properly shaped for the end use without being cut or sewn. Thus, in some embodiments, a spacer fabric described herein is not cut or sewn, including for incorporation into a product or before incorporation into a product, such as a product described below.
  • a spacer fabric described herein is a footwear application.
  • a spacer fabric described herein for example, can be used as a separate and removable insole of a shoe.
  • a spacer fabric described herein may also be used to form a complete knit shoe upper with an integral spacer fabric sole/insole.
  • a spacer fabric described herein can be used in footwear such as socks.
  • a spacer fabric described herein can be an apparel application.
  • a spacer fabric described herein can be used in safety and sportswear components and garments, particularly components and garments in which cushioning regions may be desirable for impact resistance and protection in certain areas for force dampening from impact.
  • spacer fabrics described herein can be configured to provide impact resistance in certain zones of the apparel, such as for use in high impact and dangerous sports such as football, cross country cycling and many others in which elbows, knees, hips, shins and skulls, and other bodily regions need cushioning from severe impact.
  • a spacer fabric described herein is a seating application.
  • a spacer fabric can be used to form all or a portion of a chair back and/or seat for offices, homes, hospitals, wheel chairs, schools, automobiles, motorcycles, bicycles, lawn mowers, and other vehicles and devices.
  • a seating component formed from a spacer fabric having differing zones, as described above can help protect and support the body of a user from impact, including with reference to pressure mapping of the seating component when in use.
  • a spacer fabric described herein is used in bedding applications.
  • a spacer fabric described herein can be used to provide a complete sleeping support surface, or to provide a component or element of a mattress.
  • the spacer fabric can provide additional support and ventilation.
  • the three-dimensional structure of spacer fabrics described herein which can include primarily void spaces/air as described above, without filaments extending between upper and lower surfaces, can facilitate or enable improved ventilation of the body of a user in contact with the spacer fabrics.
  • Spacer fabrics described herein can also help maintain a user of the spacer fabrics at a desired temperature for the relevant end uses of the spacer fabrics.
  • Methods described herein can be carried out in any manner not inconsistent with the objectives of the present invention.
  • a method described herein is carried out using a knitting machine. More particularly, in some embodiments, a method described herein is carried out using a weft knitting machine having at least two sets of needles.
  • the knitting machine is a flat bed knitting machine having a front needle bed and a back needle bed. In other cases, the knitting machine is a circular knitting machine having a cylinder set of needles and a dial set of needles.
  • a knitting machine used in a method described herein can be automated.
  • a knitting machine is configured to carry out a knitting process according to needle-by-needle or stitch-by-stitch instructions provided by a computer as a function of space and/or time.
  • the computer can include a processor and a memory storing computer-readable program code portions that, in response to execution by the processor, cause instructions to be provided to one or more components of a knitting machine in a desired sequence.
  • spacer fabrics are described herein.
  • the spacer fabrics can be formed in any manner described in Section I hereinabove and can have any features or properties of spacer fabrics described hereinabove in Section I.
  • a spacer fabric described herein comprises a knit structure formed from a first yarn and a second yarn, wherein the knit structure comprises a plurality of concave portions in facing opposition to a plurality of convex portions, the concave portions and the convex portions defining void spaces having a substantially double convex cross section.
  • the first yarn is a low thermal shrinkage yarn
  • the second yarn is a high thermal shrinkage yarn.
  • the knit structure is a unitary knit structure.
  • first and second yarns of a spacer fabric described herein can have any properties, including any properties relative to one another, not inconsistent with the objectives of the present disclosure.
  • the second yarn of the spacer fabric shrinks at least twice as much as the first yarn in at least one dimension at a heat shrinking temperature between 50°C and 150°C.
  • heating the knit structure of the spacer fabric at a temperature sufficient to cause shrinkage of the second yarn by at least 10% in at least one dimension increases a size of the void spaces in a thickness direction of the fabric, including in a manner described hereinabove.
  • a spacer fabric described herein, when unheated, is flat or substantially flat. Further, in some embodiments, a thickness of the fabric increases by at least 0.5 cm when the fabric is heated at a temperature sufficient to cause shrinkage of the second yarn by at least 10% in at least one dimension.
  • the first yarn is a monofilament yarn, such as a monocomponent monofilament yarn or a multi- component monofilament yarn. Other yarns may also be used as the first yarn. In addition, in some cases, the first yarn has a higher modulus than the second yarn. Further, in some embodiments, the second yarn is a multifilament yarn such as a monocomponent multifilament yarn or a multi-component multifilament yarn. Other second yarns may also be used.
  • the knit structure of a spacer fabric described herein is formed from a third yarn in addition to the first yarn and the second yarn, the third yarn differing from the first yarn and the second yarn.
  • Any third yarn not inconsistent with the objectives of the present disclosure may be used, including a third yarn described hereinabove in Section I.
  • the third yarn is a thermally fusible yarn, such as a third yarn that is thermally or heat-fusible at a temperature sufficient to cause the second yarn to shrink by at least 10% in at least one dimension.
  • the knit structure of a spacer fabric described herein is formed from a fourth yarn in addition to the first yarn, the second yarn, and the third yarn of the knit structure, wherein the fourth yarn differs from the first yarn, the second yarn, and the third yarn.
  • Any fourth yarn not inconsistent with the objectives of the present disclosure may be used, including a fourth yarn described hereinabove in Section I.
  • the fourth yarn has a color, texture, denier, and/or elasticity that differs from a color, texture, denier, and/or elasticity of the first yarn, the second, yarn, and/or the third yarn.
  • a spacer fabric described herein can comprise a plurality of differing zones, the zones having one or more differing properties.
  • the fabric comprises a plurality of zones having different compression resistances in a thickness direction of the fabric.
  • the fabric has one or more first zones of low compression resistance and one or more second zones of high compression resistance, such as one or more first zones having a compression resistance of no more than 30 psi and one or more second zones having a compression resistance of at least 50 psi.
  • the locations of such zones in some instances, correspond to a pressure map of the fabric when in use in an end application, including an end application described above.
  • a spacer fabric described herein can be used in a variety of end use applications.
  • a spacer fabric described herein forms a portion of a seat or seat back.
  • a spacer fabric described herein forms a portion of footwear.
  • a minimum of two (A+B), and more preferably three (A+B+C) material yarns were used in the following examples. Additional types of yarn could be added for color, texture, or other aesthetic or performance properties if desired, as described above.
  • This yarn type was used to make up the rigid skeleton portion of the spacer fabric, which provides one of two important elements of the 3D structure, and cushioning of the fabric.
  • This Yarn A was typically a stiff higher modulus monofilament yarn that provides the primary stiffening agent in the fabric and the knit construction. Together with the yarn composition and modulus of the yarn as well as subsequent heat setting, these features all work together to provide the major contributors to the fabric's compressive resistance.
  • Yarn A in some cases, is as follows:
  • Multi-component e.g., Biocomponent
  • Typical polymers could be based on polyester, polyamide, polypropylene (or other polyolefins), and other melt processing polymers that can be extruded into monofilament yarns.
  • the multi- component monofilament yarn(s) could have a lower melting sheath material on the external coating of the yarn which would melt and flow to the adjacent yarns when the knitted fabric is heated after the knitting operation.
  • Yarns of the Yarn B type can typically be multifilament yarns for softness, high coverage, and easier knitting. But monofilaments could be used as well.
  • Type B yarns can be of different types, such as:
  • Multi-component e.g., Bicomponent
  • Multi-component e.g., Bicomponent Multifilament.
  • Typical polymers can be based on polyester, polyamide, polypropylene (or other polyolefins), and other melt processing polymers that can be extruded into multifilament yarns.
  • These (optional) yarns have a low melting point, and can serve as bonding materials to keep the fabric from losing form, and improve memory (resistance to permanent deformation due to cyclic compressive loading).
  • These yarns can be of different types, such as:
  • weft knit spacer fabrics described herein can be made on any weft knitting machine with a minimum of 2 sets of needles in either (F B + BNB for Flat bed Machines, or Cylinder and Dial for Circular weft knitting Machines), and on any machine gauge, typically ranging from 5 gauge to 18 gauge (the number refers to the needles per inch in each of the respective needle beds). The gauges can be even finer if the knitting process is run on circular machines (the larger the number, the finer the gauge).
  • the yarn sizes can be based on the gauge of the equipment used to form the fabric. For example, on a 6.2 machine (12 gauge) the low shrinkage yarns could range from
  • the knitting process in example embodiments described herein can be considered to comprise mirroring concave and convex structures made of the low shrinkage monofilament yarn, and then knitting the high shrinkage and fusible yarns in a similar fashion to cover the skeleton.
  • FIGs. 1A-1C Different fabric patterns were accomplished using this technique, such as the fabric patterns illustrated in FIGs. 1A-1C.
  • Each spacer fabric (100 A, 100B, and lOOC) illustrated in FIGs. 1A-1C was knitted from at least a first yarn and a second yarn to form the knit structures (which may also be denoted as 100A, 100B, and lOOC).
  • the knit structures including various portions, regions, or zones 102.
  • the knit structures comprise or are formed from a plurality of opposing concave and convex portions that define a plurality of void spaces 106.
  • FIG. 1A is a perspective view of a first spacer fabric 100A comprising a plurality of repeating diamond shapes or patterns 102.
  • FIG. 1A is a perspective view of a first spacer fabric 100A comprising a plurality of repeating diamond shapes or patterns 102.
  • FIG. 1A is a perspective view of a first spacer fabric 100A comprising a plurality of repeat
  • IB is a perspective view of a second spacer fabric 100B comprising a plurality of ribs 102
  • FIG. 1C is a third spacer fabric lOOC comprising a plurality of repeating rectangular shapes or patterns 102. Other patterns can also be accomplished and are contemplated herein.
  • FIG. 2 is a schematic illustration of a sectional view of a spacer fabric according to some embodiments described herein.
  • FIG. 2 illustrates both a pre-processed spacer fabric 200A and a post-processed spacer fabric 200B.
  • the post-processed spacer fabric 200B has been heated to a temperature sufficient to shrink the high-shrinkage and fusible yarns forming the fabric.
  • yarn types B and C are high shrinkage yarns that shrink more than the lower shrinkage yarn type A.
  • FIG. 3 is a sectional view of a spacer fabric 300 before heating.
  • the fabric comprises a plurality of voids 302 formed therein, such voids being disposed or positioned between a first, upper portion 304 A and a second, lower portion 304B of the fabric, which faces the first portion.
  • the respective upper and lower portions 304 A and 304B of fabric are configured to form or define opposing concave and convex portions.
  • FIG. 4 is a sectional view of the spacer fabric of FIG. 3, denoted as 400 in FIG. 4, after heating in a manner described hereinabove in Section I. As FIG.
  • the plurality of void spaces 406 form and maintain a substantially double convex cross section during and after heating via shrinkage of the higher shrinkage yarn.
  • the void spaces 406 are formed in the fabric 400 between the respective upper and lower portions 404A and 404B of fabric.
  • Methods of making a spacer fabric described herein can provide fabrics that are very stable, as opposed to conventional weft knitted spacer fabrics, which tend to collapse on the wale's direction (see FIGs. 5 and 6 for illustrations of conventional spacer fabrics, for comparison with FIGs. 2-4).
  • FIG. 5 is a schematic illustration of a sectional view of a conventional weft knitted spacer fabric 500 for comparison purposes.
  • the fabric 500 includes orthogonally disposed lower shrinkage yarns 502 and higher shrinkage yarns 504, the lower shrinkage yarns 502 being prone to collapsing between the higher shrinkage yarns 504.
  • FIG. 6 is a sectional view of a conventional spacer fabric 600 which has z-direction yarns in the space 606 defined between the respective upper and lower faces 602, 604 of the overall spacer fabric.
  • Spacer fabrics according to some embodiments of the present invention have been formed that have load bearing capabilities (compressive resistance) ranging from about 4 psi to over 88 psi.
  • the compressive resistance of a specific spacer fabric can be selected based on one or more of the following:
  • Knit Construction see below for examples of different knit constructions according to various embodiments described herein.
  • FIGS. 7 and 8 illustrate various "needle diagrams" for forming spacer fabrics according to some embodiments described herein.
  • FIG. 7 is a needle diagram corresponding to an 1 lxl 1 needle tubular rib pattern.
  • FIG. 8 is a needle diagram corresponding to an 1 lxl 1 needle tubular squares pattern.
  • FIGs. 9A-9F are additional needle diagrams showing variations of the methods described herein.
  • rows of needles correspond to steps in specific knitting processes, where stitches on needles are shown. Additionally, certain rows of needles are marked with the type of yarn used (e.g., as yarn of Yarn A type or Yarn B type). Additionally, it is understood that not every row is so marked. However, as persons skilled in the art will appreciate, the type of a given row can be determined based on repetition of the identified patterns (e.g., repeating ribs, diamonds, squares, rectangles, etc.).

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Abstract

Selon un aspect, la présente invention concerne des procédés de fabrication d'un tissu de séparation. Selon certains modes de réalisation, un procédé comprend le tricotage d'un premier fil ou d'une première fibre et d'un second fil ou d'une seconde fibre pour former une structure tricotée, la structure tricotée comprenant une pluralité de parties concaves placée en opposition face à une pluralité de parties convexes. En outre, les parties concaves et les parties convexes définissent ensemble des espaces vides ayant une section transversale convexe sensiblement double. Dans certains cas, le procédé comprend en outre le chauffage de la structure tricotée à une température suffisante pour amener le second fil ou la seconde fibre à se rétracter dans au moins une dimension. De plus, le second fil ou la seconde fibre se rétracte plus que le premier fil ou la première fibre pendant l'étape de chauffage. De plus, dans certains cas, le chauffage de la structure tricotée augmente la taille des espaces vides de la structure tricotée, en particulier dans une direction d'épaisseur du tissu.
PCT/US2018/016081 2017-02-01 2018-01-31 Tissus de séparation et procédés de fabrication de tels tissus de séparation Ceased WO2018144504A1 (fr)

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US16/482,607 US20200002855A1 (en) 2017-02-01 2018-01-31 Spacer fabrics and methods of making the same
EP18747357.4A EP3577264A4 (fr) 2017-02-01 2018-01-31 Tissus de séparation et procédés de fabrication de tels tissus de séparation
US18/450,555 US20230392306A1 (en) 2017-02-01 2023-08-16 Spacer fabrics and methods of making the same

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US62/453,147 2017-02-01

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