CUT-RESISTANT AND MOISTURE MANAGEMENT COOLING FABRIC, ARTICLE FORMED OF CUT-RESISTANT AND MOISTURE MANAGEMENT COOLING FABRIC, AND METHOD OF MAKING CUT-RESISTANT AND MOISTURE MANAGEMENT COOLING FABRIC

A multi-layered knitted fabric includes: a first layer formed of a first yarn; a second layer formed of a second yarn; and a third layer formed of a third yarn. The first yarn includes an evaporative yarn, the second yarn includes a cut resistant yarn, the third yarn includes an evaporative yarn adapted to allow moisture trapped in the second layer to move to the third layer, and the second layer is arranged between the first and third layers.

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Description
INCORPORATION BY REFERENCE

The present application expressly incorporates herein in their entireties: U.S. patent application Ser. No. 16/077,353; U.S. patent application Ser. No. 16/100,939; U.S. patent application Ser. No. 16/481,226; U.S. patent application Ser. No. 16/749,016; U.S. patent application Ser. No. 17/322,163; U.S. patent application Ser. No. 17/329,464; U.S. Pat. Nos. 11,008,681; 11,015,271; 10,428,448; and PCT Application No. PCT/US2020/041593.

FIELD OF THE INVENTION

The present invention relates to a cut-resistant and cooling fabric, an article formed of a cut-resistant and moisture management cooling fabric, and to a method of making a cut-resistant and moisture management cooling fabric. The article may be an article of clothing, such as a glove, sleeve, etc., or portion thereof. BACKGROUND INFORMATION

Conventional cut resistant gloves do not have moisture management performance, and may repel moisture on the inside of the glove, rather than absorbing moisture. Therefore, conventional cut resistant gloves may become uncomfortable to the wearer over time, for example, after heavy lifting, manual labor, etc. Similar issues arise for the wearer of cut resistant sleeves. Certain industrial and residential jobs, such as, for example, manufacturing, sheet metal production, metal stamping, food production or processing, e.g., dicing or slicing of meats, vegetables, produce, etc., require ANSI rated cut resistant gloves and sleeves. According to, for example, the ANSI/ISEA 105-2016 standard, which is based on the ASTM F2992-15 testing method, describes cut resistance for industrial work gloves on a scale of A1, i.e., the lowest level or protection, to A9, i.e., the highest level of protection, based on the weight, measured in grams, required to cut through the material of which the work glove is formed. The ANSI/ISEA 105-2016 rating scale is summarized below.

Minimum weight (in grams) required ANSI/ISEA to cut through the 105-2016 Level material Typical Use A1 200 General purpose; warehouse; assembly of small parts A2 500 General purpose; molding and injection molding of plastics; pulp and paper manufacturing A3 1,000 Handling of raw materials; general manufacturing; construction A4 1,500 HVAC installation, maintenance, and service; aerospace applications; food preparation A5 2,200 Handling of glass and sheet metal; automotive assembly; HVAC installation, maintenance, and service A6 3,000 Metal fabrication; glass manufacturing; handling of cutting blades A7 4,000 Preparation and processing of meats; glass manufacturing; metal stamping A8 5,000 Metal stamping; recycling of metals and glass; heavy assembly A9 6,000 Stamping of sharp metals; sorting of recycled metals and glass; metal fabrication

Another measure of cut resistance is described in EN388:2016, which describe cut resistance on a scale of A, i.e., the lowest level of cut resistance, to F, i.e., the highest level of cut resistance, based on force, measured in newtons, required to cut through the material of which the glove is formed. The EN388:2016 rating scale is summarized below.

EN388:2016 Performance Force (measured in newtons) required to cut Level Rating through the material A 2 B 5 C 10 D 15 E 22 F 30

Furthermore, cuts and lacerations are among the most frequent types of injury in the workplace. Moreover, workers are prone to remove gloves when their hands and arms are sweaty and hot. If not careful, workers may try to by-pass the safety requirements of wearing cut resistant gloves and sleeves just to stay cool and comfortable. Accordingly, it would be beneficial for cut resistant gloves and sleeves to have the ability to keep the wearer's hands and arms cool by managing the moisture generated from sweat.

Previous cut resistant gloves and sleeves use flatbed (V-bed) or circular knitting methods and typically use yarns designed for meeting the cut resistance level necessary to meet safety requirements. In some rare cases, existing commercial gloves contain moisture management yarns. However, these yarns are not knitted in the proper manner to create moisture removal in one-direction away from the skin and are used to provide aesthetics such as color to the end product. The use of yarns not designed to provide moisture management therefore creates a wet and humid experience next to the skin and can lead to discomfort. This discomfort could cause the wearer of the cut resistant gloves to remove the gloves more often, leading to injury. Therefore, a need is believed to exist for a moisture management cooling glove that is capable of removing moisture away from the skin, employing a more advanced yarn and construction technique that can provide sustained moisture management to produce a cooling effect and provide a higher sweat removal and dryness next to skin, increasing the wearer's comfort level.

SUMMARY

Described herein is a method of knitting cut resistant gloves, sleeves, other articles, garments, textiles, etc., which exhibit excellent moisture management properties and exceed the performance for similar existing commercial products for wicking, absorbency, dry rate, one-way moisture transport, cooling power, and moisture vapor removal, etc.

Example embodiments provide a method of adding moisture management performance to ANSI rated cut resistant gloves and sleeves through use of moisture management yarns and knitting construction methods. Therefore, example embodiments of the present invention provide cut resistant and cooling fabrics, articles, e.g., garments, articles of clothing, gloves, sleeves, portions thereof, formed of a cut-resistant and cooling fabric, and methods of making a cut-resistant and cooling fabric.

According to an example embodiment of the present invention, a multi-layered knitted fabric includes: a first layer formed of first yarn; a second layer formed of a second yarn; and a third layer formed of a third yarn. The first yarn includes evaporative synthetic cooling yarn(s), the second yarn incudes cut resistant yarn(s), and the third yarn includes evaporative synthetic cooling yarns(s). This combination of yarns is knitted into a fabric construction adapted to allow moisture trapped next to skin to move in one direction from the skin side layer, through the middle layer, and to the outside. Once the moisture reaches the outside surface, the evaporative synthetic yarn(s) spread the moisture for effective evaporation. The yarn(s) in layers 1 and 2 are fed into feed 1 of a flatbed knitting machine (e.g., a Shima Seiki model SWG041N2 18 gauge), whereas the yarn(s) in layer 3 is fed into Feed 2.

The second layer may be arranged adjacent the first layer.

The third layer may be arranged adjacent the second layer.

The first layer may include an evaporative synthetic cooling yarn.

The second layer may include a cut resistant yarn.

The multi-layered knit cooling fabric may have a density of 100 to 2000 g/m2.

The third layer may include an evaporative synthetic cooling yarn.

The fabric may form an entire garment, e.g., a glove and/or a sleeve.

The fabric may be integrated into a garment, e.g., a glove and/or a sleeve.

The first layer may be adapted to be worn against skin.

The first layer may include a combination of a stretchable synthetic yarn and the evaporative yarn.

The third layer may be adapted to be exposed to an external environment.

The second layer may be arranged between the first layer and the third layer.

The first layer may include hydrophobic and hydrophilic channels.

The cut resistant yarn may include tungsten, steel, and/or high-density polyethylene.

The cut resistant yarns may include 100 to 1000 Denier high-density polyethylene yarn and/or 10 to 100 micron tungsten and/or steel monofilament yarn, 20 Denier to 150 Denier spandex for stretch performance, and a combination of 20 to 150 Denier nylon and 20 to 1500 Denier nylon to impart strength and color to the product. Furthermore, the evaporative yarn and/or the absorbent yarn used in combination with the cut resistant yarns may include 65 Denier/68 filament to 75 Denier/72 draw textured filament polyester and/or nylon yarn and/or Denier/12 filament to 70 Denier/72 filament fully drawn or draw textured filament polyester and/or nylon yarn. Placement and construction using these yarns provide moisture removal performance.

A cut resistant glove may use a 100 Denier HDPE in combination with 70 Denier plus Denier Blue Polyamide (ylon) and may be knit on an 18 gauge Shima Seiki knitting machine, e.g., a Shima Seiki SWG041N2 machine. The cut resistance yarns may include 40 Denier spandex and a 15 micron tungsten monofilament wire. Using the cut resistance yarns in Feed 1 and by adding 65 Denier, 68 Filament ASKIN Draw Textured Yarn Polyester to these yarns in Feed 1 plus a 50 Denier, 24 Filament Aqua X Fully Drawn Nylon or ASKIN Fully Drawn Polyester in Feed 2 provides moisture management performance described more detail below. Adding moisture management yarns in proper ratio to cut resistance yarns improves the moisture management performance of the cut resistance glove, sleeve, etc.

Further features and aspects of example embodiments of the present invention are described in more detail below with reference to the appended schematic Figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a representational cross-sectional view of a cut resistant and cooling fabric, e.g., forming a glove, showing the different layers of the fabric.

FIGS. 2A to 2E are cross sectional views of yarn filaments used in construction of the fabric.

FIGS. 3A to 3J illustrate single knit, flatbed (V-bed), or double knit jersey stitch structures that may be utilized for constructing an article, e.g., a glove, and FIG. 3K illustrates a legend for a further understanding of FIGS. 3A to 3J.

FIG. 4 illustrates a single knit construction.

FIG. 5 illustrates an article, e.g., a glove, including portion(s) formed of a cut resistant and cooling fabric.

FIGS. 6A to 6D illustrate yarns for use in seamless knitting constructions.

FIG. 7 illustrates the yarns of FIGS. 6A to 6D used in a seamless knit construction.

FIGS. 8A to 8C illustrate knit loop, tuck look, and float loop knitting that may be used in example embodiments of the present invention.

 DETAILED DESCRIPTION

As shown in FIG. 1, an example embodiment of a cut resistant and cooling fabric 100 includes, for example, multiple layers 104, 106, 108. It should be understood that the fabric 100 may include only a single layer. The fabric is intended to be worn next to the skin 102 of a user, such as a worker. The fabric 100 may be used to form articles, e.g., garments, articles of clothing, gloves, sleeves, portions thereof, e.g., the palm of a glove, the individual finger(s) of a glove, etc. The fabric 100 may form an entire garment, such as an entire glove or sleeve, or may be selectively and strategically integrated into garments where extra cut-resistance and/or cooling is needed, such as near the palm or fingers of a user. The fabric 100 may also be utilized to form standalone cut resistant and cooling product.

The layers of fabric 100 depicted in FIG. 1 in cross-section are shown separated for clarity and illustrative purposes. In an actual manufactured fabric, the different layers 104, 106, 108 may be interconnected in a knit construction as described herein, for example.

A first layer 104 of the fabric 100, to be warn against the skin 102, is formed, for example, of a combination of a cut resistant synthetic yarn and an evaporative synthetic cooling yarn. The evaporative synthetic cooling yarn may be constructed as described, for example, in U.S. patent application Ser. No. 16/077,353, U.S. patent application Ser. No. 16/100,939, U.S. patent application Ser. No. 16/481,226, U.S. patent application Ser. No. 16/749,016, U.S. patent application Ser. No. 17/322,163, U.S. patent application Ser. No. 17/329,464, U.S. Pat. Nos. 11,008,681, 11,015,271, 10,428,448, and/or PCT Application No. PCT/US2020/041593, each of which is expressly incorporated herein in its entirety by reference thereto.

The evaporative synthetic cooling yarn may include stretchable synthetic yarn(s) and evaporative yarn(s). Suitable stretchable synthetic yarns include, but are not limited to, spandex, lycra, elastane, etc. A cross-section of a single filament of a stretchable synthetic yarn, such as spandex, is depicted in FIG. 2D. However, the spandex may be omitted from first layer 104 if stretch or draping qualities are not needed for fabric 100.

The evaporative yarn of first layer 104, together with cut resistant yarns, which include spandex, tungsten monofilament wire, and HDPE yarns, creates hydrophobic and hydrophilic channels for perspiration to enter and travel through the center of the fabric. For example, perspiration may enter the absorbent center of fabric 100 while also allowing the chilled (e.g., 60° F.) center to provide conductive cooling against skin 102 (e.g., at an average skin temperature of 93.2° F.) as indicated by the arrows in FIG. 1 near skin 102. The evaporative yarn of first layer 104 may be or include, for example, a nylon or polyester yarn having a unique cross-section (as illustrated, for example, in FIG. 2A) and may be embedded with minerals (e.g., jade or mica) to transport and evaporate moisture from skin 102 while still providing conductive cooling from center layer 106 while also a cooling touch from layer 104. Examples of suitable evaporative yarns include AQUA-X and ASKIN, both manufactured by Hyosung Corporation of the Republic of Korea, both of which may also provide UV protection.

The cut resistant and cooling yarn combination utilized in fabric 100 allows for absorption of water to occur while transporting water efficiently through fabric 100 to create a drier inside surface and speed evaporation on the outside due to moisture movement through the fabric 100 or article, e.g., glove, made therefrom. Thus, for example, one-way moisture movement from the skin 102 toward inside of fabric surface 104 of fabric toward the exterior side of the fabric 108 may be achieved as indicated by arrow 110.

The second layer 106 of fabric 100 is partially formed from a highly evaporative synthetic cooling yarn adapted to absorb and hold a portion of the moisture that is wicked from skin 102 by first layer 104. This is due to this layer containing both evaporative synthetic yarn plus the hydrophobic cut resistant yarns such as HDPE, tungsten, and spandex. The absorbance of the second layer 106 may also provide a cooling effect to skin 102. That is, because the second layer 106 is able to retain a quantity of cooled water when it gets wet while still providing the ability to absorb wicked moisture from the skin side 102. The second layer 106 is cooled through the adjacency to third evaporative layer 108.

The third layer 108 of fabric 100 is formed from a yarn designed to transport moisture and provide a cool touch. The third layer 108 allows the moisture trapped in second layer 106 to evaporate into the ambient air and also allows ambient air to move into second layer 106 to cool the center of cooling fabric 100. A cross-section of a single filament of a yarn suitable for use in third layer 108 is depicted in FIG. 2C.

The cooling effect for fabric 100 follows the principles of evaporative cooling. This principle details that water must have heat applied to change from a liquid to a vapor. Once evaporation occurs, this heat from the liquid water is taken due to evaporation resulting in cooler liquid. Once the fabric 100 is wetted with sweat or water and, for example, normal wearing of the cooling fabric may help facilitate and expedite the moisture movement from the second layer 106, where water is stored, to the outer evaporative layer 108, where water evaporation occurs. Movement of normal wearing may help increase the evaporation rate and decreases the material temperature more rapidly by exposing more surface area of the material to air and increased air flow. More specifically, the fabric 100 is adapted to facilitate and expedite the evaporative process. The moisture taken from the skin is therefore transported in one direction to the outside surface where the moisture can evaporate more efficiently and furthermore creates a higher conductive cooling back to the skins surface. In addition, a wearer may more efficiently evaporate sweat and feel cooler as sweat does not sit on the skin 102 but absorbed into fabric 100 on layer beginning on layer 104.

Once the temperature of the remaining water in the outer evaporative layer 108 drops through evaporation, a heat exchange happens within water through convection, between water and fabric through conduction, and within fabric through conduction. Thus, the temperature of fabric 100 drops. The evaporation process further continues by wicking water away from the layer 106 to layer 108 until the stored water is used up. The evaporation rate decreases as the temperature of fabric 100 drops. The temperature of fabric 100 drops gradually to a certain point where equilibrium is reached between the rate of heat absorption into material from environment and heat release by evaporation.

Once the wetted fabric 100 is placed onto one's skin, cooling energy from the fabric 100 is transferred through conduction. After the cooling energy transfer has occurred, the temperature of the fabric 100 increases to equilibrate with the skin temperature. Once this occurs, the wetted fabric 100 can easily be re-activated through more sweat generation and normal wearing of the fabric to enhance evaporation through exposure to air and increased air flow.

The various views depicted in FIGS. 2A to 2E are cross-sectional diagrams of a single filament used in the different yarns for layers 104 to 108. However, each yarn may multiple filaments.

The yarn combination utilized in fabric 100 allows for more absorption of water to occur while transporting water efficiently through fabric 100 to create a one-directional moisture movement while also providing an evaporative cooling effect which increases the conductive cooling effect of fabric 100. Further benefits of fabric 100 include:

    • One-directional moisture movement (which may be measured according to AATCC 195) of 998% before wash and 2141% after wash from layer 104 to layer 108.
    • Increased absorbency next to skin on Layer 104 before and after wash (which may be measured according to AATCC 79).
    • Increased wicking distance on the outer layer 108 before and after wash (which may be measured according to AATCC 197).
    • Cool touch provided by first layer 104 (against skin 102) when the fabric 100 is dry. A cool touch fabric is a fabric that physically feels cooler than the ambient air when touched by a user, whether wet or dry.
    • Up to a 243% increase in conductive cooling power measured in Watts/m2 when compared to the same fabric without evaporative cooling yarn and normal knitting construction.
    • Overall Moisture Management Score (which may be measured according to AATCC 195) of at least 4 out of 5 (5 being the highest); conventional cut resistant gloves may score 1 out of 5.
    • Overall Moisture Vapor Transmission Rate of 1975% (which may be measured according to ASTM E96); conventional cut resistant gloves may have an Overall Moisture Vapor Transmission Rate of 1576%.
    • Overall Dry Rate of 0.9132 mL/hr before wash and 0.9624 mL/hr after wash (which may be measured according to AATCC 201); conventional cut resistant gloves may have an Overall Dry Rate of 0.4908 mL/hr before wash and 0.5136 mL/hr after wash.

FIGS. 3A to 3J illustrate single knit and double knit structures that may be utilized for constructing an article, e.g., a glove, and FIG. 3K illustrates a legend for a further understanding of FIGS. 3A to 3J, e.g., illustrating knit, tuck, and miss stitches. These structures can also be applied to flatbed or V-bed knitting for applications on a machines such as Shima Seiki. FIG. 3A illustrates an all knit single knit structure, FIG. 3B illustrates a knit and tuck single knit structure, FIG. 3C illustrates a knit and miss single knit structure, FIG. 3D illustrates another knit and miss single knit structure, FIG. 3E illustrates a 1×1 rib double knit structure, FIG. 3F illustrates a half cardigan double knit structure, FIG. 3G illustrates a full cardigan double knit structure, FIG. 3H illustrates a half Milano double knit structure, FIG. 3I illustrates a full Milano double knit structure, and FIG. 3J illustrates an interlock double knit structure.

FIG. 4 illustrates a V-bed jersey knit construction and how yarns are fed into knitting machine to impart, for example, absorbing, wicking, drying, and/or one-way moisture movement abilities to fabric 100 and/or an article, e.g., a glove, formed thereof. As illustrated in FIG. 4, two feeds, e.g., first feed 202, second feed 204, may be provided in each course. First feed 202 may include cooling and cut resistant yarns. For example, first feed 202 may include a cooling yarn, such as 65 Denier/68 filament polyester cooling yarn, and cut resistant yarn(s), such as 100 Denier/40 filament high density polyethylene (HDPE), 70 Denier HDPE, Denier spandex, tungsten filament, etc. and Second feed 204 may include a cooling yarn, e.g., 50 Denier/24 filament nylon yarn.

FIG. 4 also illustrates V-bed jersey construction and how yarns are fed into a single knit knitting machine to impart, for example, absorbing, wicking, drying, and/or one-way moisture movement abilities to fabric 100 and/or an article, e.g., a glove, formed thereof. As illustrated in FIG. 5, a feed 302 is provided in each course. The feed 202 may include a 400D HDPE+100D Fiberglass+2 ends of 75D Poly in Feed 1. Feed 204 may include 2 ends of 50/24 Nylon.

It should be appreciated that FIG. 4 illustrates the side of the fabric facing the skin and that the legs of the loops touch the skin to absorb moisture, e.g., by the greater surface area in contact with the skin. This is in contrast to conventional constructions in which the legs of the loops are knitted on the outside of the fabric, e.g., glove. Thus, for example, after knitting, the fabric or article, e.g., glove, sleeve, etc., may need to be flipped or turned inside-out to form the skin-side of the fabric or article.

FIG. 5 illustrates an article, e.g., a glove 1400, that includes portions formed of a cut resistant and cooling fabric as described herein. The glove 1400 includes a number of regions 1402, 1404, 1406, 1408. Regions 1402 and 1402 are located on the top side of the glove 1400, e.g., the side of the hand opposite the palm, and region 408 is located on a palm side of the glove 1400. Region 1406, corresponding to the cuff of the glove 1400, extends entirely around the circumference of the cuff. Region 1402 may provide for rapid moisture removal, region 1404 may provide for moisture vapor removal, region 1406 may provide for high cooling power and may be light weight and breathable, and region 1408 may provide for instant cool touch and moisture wicking and may include a grip enhancing coating.

Thus, as described herein, fabric 100, and/or article(s) made from fabric 100, may be formed utilizing V-bed (on equipment such as that produced by Shima Seiki) or seamless knitting construction techniques. As compared with convention cut resistant articles, e.g., gloves, which may grade as “Poor” or “1” according to the American Association of Textile Chemists and Colorists (AATCC) Test Method 195, articles, e.g., gloves, formed of fabric 100 described herein may achieve a grade of “Excellent” or “5” (or “4” to “5”). In terms of moisture absorbency, conventional cut resistant articles, e.g., gloves, may not absorb moisture, according to AATCC Test Method 79, whereas, in articles, e.g., gloves, formed of fabric 100 described herein, moisture absorbency may be created and moisture may be absorbed on both sides of the fabric in, for example, 30.4 seconds or less. Wicking may also be improved by the fabric 100 described herein. For example, in convention articles, wicking, according to AATCC Test Method 197, may achieve wicking of 62 mm in the length direction and 47 mm in the width direction, whereas, in articles, e.g., gloves, formed of fabric 100 described herein, wicking of 122 mm may be achieved in the length direction and 84 mm in the width direction, e.g., an increase in wicking distance of 97% in length direction and 79% in width direction. Conventional articles may achieve a dry rate, according to AATCC Test Method 201, of 0.49 milliliters/hour, whereas, in articles, e.g., gloves formed of fabric 100 described herein, may achieve a dry rate of 0.9132 milliliters/hour, e.g., drying at a rate that is 86% higher than conventional articles. Additionally, while conventional articles, e.g., gloves, may score negative 1101% in a one-way moisture removal or transport ability, whereas, in articles, e.g., gloves, formed of fabric 100 described herein, may score positive 998% for one-way transport capability. In this regard, a positive score means moisture travels away from skin to the outside surface of the article, e.g., glove, where it can evaporate, and a negative score means the moisture is trapped on the inside of the article, e.g., glove, where it cannot escape to evaporate. In articles, e.g., gloves, formed of fabric 100 described herein, a moisture vapor removal of 1975 grams of moisture vapor removal over a 24 hour period may be achieved compared to conventional articles having the ability to remove 1586 grams of moisture over a 24 hour period. An article, e.g., a glove, formed of fabric 100 described herein may conduct 16,141 watts of cooling energy when wetted as compared to 6,632 watts of cooling energy when wetted for conventional articles. Moreover, articles, e.g., gloves, formed of fabric 100 described herein may also achieve greater cooling to the initial touch than conventional articles.

According to example embodiments of the present invention, particular yarn combinations of synthetic filament yarns and cut resistant yarns are used to achieve particular effects to add cooling properties absorbency, moisture transport, wicking, cooling power, cool touch, evaporation, etc., to the fabric 100 and articles formed therefrom. For example, particular synthetic filament yarns are added to the construction to aid in moisture transport and evaporation. These yarns may have or include a modified cross-section to aid in the material's ability to wick and transport moisture. These yarns may also include embedded cooling particle technology to increase the thermal effusivity (cool touch) of the material on the skin contact side. The fabric 100 can absorb undesirable sweat for the life of the product as the moisture absorbing, wicking, transport, etc., properties are not achieved by topical chemical treatments. The fabric 100 or articles formed therefrom may be treated with antimicrobial chemicals and/or may include particular yarns to inhibit microbe growth, thereby making it, for example, odor free after repeated usage and wash care. The fabric 100, or an article formed therefrom, may dry soft and may be re-useable, e.g., the fabric 100, or articles made therefrom, may be machine washed and machine dried.

Accordingly, it should be appreciated that V-bed (flatbed) knitted or seamless knitted construction techniques described herein may create a material that outperforms conventional cut resistant articles, e.g., gloves, and can permanently provide improved absorbing, wicking, moisture management, dry rate, thermal effusivity, moisture vapor removal properties, by, for example, adding moisture management yarns to the material during the knitting process. The fabric 100, as noted above, does not require added chemicals to achieve the lasting effect. Thus, example embodiments of the present invention may: (1) achieve higher moisture management properties to produce higher absorbency, dry rate, wicking, moisture transport, and moisture vapor removal, and good thermal effusivity; (2) dry 86% more moisture than conventional articles; (3) stay 900% drier on the inside of an article, e.g., glove, once sweat starts, compared to conventional articles; (4) provide increased moisture absorbency and wicking properties; (5) provide for removal of 33% higher moisture vapor; (6) produce a higher cooling power once wet to conductively cool skin; and (7) have good cool to the touch properties.

According to an example embodiment, flatbed and seamless knitting construction techniques may utilize cut resistant and cooling yarns. The cut resistant yarns may include, for example, 100 to 1000 Denier high density polyethylene yarn, 10 to 100 micron tungsten or steel monofilament yarn, etc., and the cooling yarns may include, for example, 65 Denier/68 filament to 75 Denier/72 draw textured filament polyester or nylon yarn, 30 Denier/12 filament to 70 Denier/72 filament draw textured filament polyester or nylon yarn, etc. The weight range may be, for example, 100 to 1500 gsm. Fiber contents may be in the following ranges, for example: (1) 45.64% HDPE, 40.27% nylon, 10.74% polyester, 3.35% spandex; (2) 42.63% HDPE, 35.91% tungsten, 12.51% polyester, 5.11% spandex, 3.84% rubber; (3) 54.5% HDPE, 23.42% nylon, 9.9% polyester, 8.85% spandex, 3.33% rubber; (4) 57.87% HDPE, 29.16% nylon, 8.12% polyester, 3.43% spandex, 1.42% rubber; etc. For example, 10 gg to 24 gg flatbed and seamless knitting may be employed. A variety of yarn combinations may be provided and may be utilized to produce different results or effects. For example, a wicking, absorbing, drying, and one-way moisture removal glove may be produced utilizing, for the fingers and palm portions of the glove, 18 gg jersey stitch using a cut resistant yarn combination with two cooling yarns (ASKIN 65/68 for feed 1 and AQUA-X 50/24 for feed 2), and, for the top of the hand portion of the glove, 18 gg 1 tuck, 1 needle with two cooling yarns (ASKIN 65/68 for feed 1 and AQUA-X 50/24 for feed 2), or, for the fingers and palm portions of the glove, 18 gg jersey with two cooling yarns (Hyosung ASKIN 65/68 for feed 1 and AQUA-X 50/24 for feed 2), and, for the top of the hand portion of the glove, 18 gg 1 tuck, 1 needle with two cooling yarns (Hyosung ASKIN 65/68 for feed 1 and AQUA-X 50/24 for feed 2). A moisture absorbing and wicking glove may be produced utilizing, for the fingers and palm portions of the glove, 15 gg jersey with one cooling yarn (ASKIN 65/68 for feed 2), and, for the top of the hand portion of the glove, 15 gg, 1 tuck, 1 needle with one cooling yarn (brrr 70/68 for feed 2). It should be appreciated that ASKIN 45 Denier/24 Filament SDY may be utilized instead of, or in addition to, AQUA-X yarn.

The particular cross-sections of the yarns may provide for particular effects. For example, modified cross-sections, such as those illustrated, for example, on the left-hand side and in the center of FIG. 2E, may improve the movement and spread of moisture to the outer layer of fabric, as compared to a regular synthetic fiber, as illustrated on the right-hand side of FIG. 2E. For example, a QMax value (e.g., measure of thermal transport, measured, for example, in watts/m2) of 0.130 W/cm2 may be achieved, indicating a cool-touch effect of the fabric 100. Additionally, microdenier (less than 1 Denier per filament (dpf)) yarns may be provided. Microdenier yarns may be arranged highly absorbent microfiber polyester yarns, having, for example, multiple, e.g., 72, filaments, to provide the desired absorbent properties.

Other performance yarns may be utilized to enhance evaporative and absorbency effects. Specifically, for the yarns listed in layers 104 and 108, other evaporative yarns with additional performance properties can be added, blended, or twisted with the evaporative yarns to intensify the cooling effect of fabric 100. Possible additional evaporative yarns include, but are not limited to, the following:

    • Mineral containing—For example, yarns impregnated with various minerals such as mica, jade, coconut shell, volcanic ash, etc., may be utilized. These mineral containing yarns may be added to first layer 104 or third layer 108 to provide a cool touch and/or increased evaporative performance. Mineral yarn may be used to also provide greater surface area for added evaporation power. An example of this type of mineral containing yarn is 37.5 polyester or 37.5 nylon, both of which are manufactured by Cocona, Inc. Both of these example yarns contain particles permanently embedded at the fiber level which capture and release moisture vapor. The active particles provide approximately 800% more surface area to the fiber and also provide a unique driving force to remove moisture vapor. By actively responding to body heat, the active particles use this energy from the body to accelerate the vapor movement and speed up the conversion of liquid to vapor, significantly increasing drying rates. Using highly evaporative yarns allows for increase evaporation from the absorbent layers.

A variety or combination of any of the following described constructions can impart added cooling power, duration, and lower temperatures when the fabric 100 is wetted to activate.

    • Yarn placement/position changes—The conjugate yarn used in layer 106 can also be used in other layers such as layer 104 and combined with the evaporative yarn and spandex. This added yarn provides more absorption power against the skin 102.
    • Warp Knit Seamless—A similar layering effect to that illustrated in FIG. 1 can also be achieved using a warp knit seamless. A warp knit jacquard can be utilized to create unique patterns such as but not limited to lace, fancy knits, mesh, body mapped, and other three-dimensional designs. Warp knit jacquard can creatively place highly evaporative yarns with highly absorbent yarns within the same construction to create a uniquely designed fabric with or without patterns such as mesh and graphics.
    • Circular Double Knit Interlock, Ponte, Pique—A similar layering effect to that illustrated in FIG. 1 can also be achieved using a circular knit interlock, ponte, or pique constructions. A circular knit interlock machine has the added capability of inserting additional evaporative and absorbent yarns to provided added evaporative cooling ability to the fabric.
    • V-Bed (Flatbed) knitting—A similar layering effect to that illustrated in FIG. 1 can also be achieved using a flat knitting machine. A flat knitting machine is very flexible, allowing complex stitch designs, shaped knitting and precise width adjustment. The two largest manufacturers of industrial flat knitting machines are Stoll of Germany, and Shima Seiki of Japan.
    • Seamless Knitting—A similar layering effect that is illustrated in FIG. 1 may also be achieved by using a seamless machine. A seamless machine may use multiple ends of yarn in a single feed while also being knit in tubular patterns and may be used for the creation of cut resistant arm sleeves. An example of a manufacture of a seamless machine capable of knitting the described construction is Santoni.

Furthermore, seamless constructions may require the use of a single yarn feed during construction. This single feed can be a single yarn or composed of multiple yarns during construction. A multi-filament yarn construction can be used in seamless constructions that provides the same cut resistant and cooling effects as fabric 100. FIG. 6A illustrates a first yarn construction 700 compatible with seamless constructions. As shown, the core 702 of the yarn 700 is composed of multiple filaments of a stretchable yarn such as Lycra or spandex at various deniers. Additionally, the core 702 may include multiple filaments of a highly absorbent yarn such as that used in layer 106 of fabric 100 and/or cut resistant yarn or filament(s). For example, the absorbent yarn is a conjugated bi-component polyester and nylon yarn with having filaments with a special star-shaped cross-section such as that illustrated in FIG. 2B.

The core 702 is either double covered (FIG. 6A), single-covered (FIG. 6B), air jet covered (FIG. 6C), or core spun (FIG. 6D) by multiple filaments of evaporative yarn 704 such as that used in first layer 104 and/or cut resistant yarn or filament(s). The evaporative yarn of covering 704 may be or may include a nylon or polyester yarn having filaments with a unique cross-section (as illustrated in FIG. 2A) and may be embedded with minerals (e.g., jade or mica) to transport and evaporate moisture from skin 102 to core 700 while still providing a cooling touch and cut resistance.

When yarn 700 is used in a seamless construction, the evaporative yarn, located in covering 704, rests against the skin of the user and it wicks moisture to the core 700. The moisture can then leave the fabric through covering 704 which is also exposed to the air (i.e., because it surrounds the core 700 on all sides). In this manner, yarn 700 can be used to provide a similar layering effect to that of cooling fabric 100 illustrated in FIG. 1.

An example of a seamless knit construction utilizing yarn 700 is illustrated in FIG. 7. The front and rear faces of the seamless knit fabric have different patterning. With seamless, patterns are readily altered and practically an unlimited number of patterns are available.

Other methods can also be used to form yarn 700 as depicted in FIGS. 6C and 6D. The yarn 700 depicted in FIG. 6C employs an air jet covering technique to cover core 702 (stretchable, absorbent and/or cut resistant yarns) with covering 704 (evaporative and/or cut resistant yarns). And, as depicted in FIG. 6D, the stretchable, absorbent, and/or cut resistant yarns, are wrapped with evaporative and/or cut resistant yarns and core-spun into a single yarn 700 which can also be used in seamless knit constructions.

Seamless knit constructions have the advantage of being tubular and can be used to create unique patterns to impart added or lessened cooling zones and/or cut resistant zones within the material. The yarns shown in FIGS. 6A to 6D can also be used to create woven fabrics.

In other embodiments, the yarn used in the seamless construction can be a single feed utilizing any combination of the yarns containing the filaments shown in FIGS. 2A to 2E. For example, a first yarn used in the feed may be a combination of a highly absorbent yarn, an evaporative yarn, and/or a cut resistant yarn and a second yarn may be a multiple filament spandex yarn and/or a cut resistant yarn. The highly absorbent yarn can be plaited separately into any seamless construction which also contains evaporative and/or cut resistant yarns to create a cut resistant and cooling material.

FIGS. 8A to 8C illustrate knitting techniques that may be used in connection with example embodiments of the present invention, e.g., to form articles, e.g., gloves, sleeves, etc. FIG. 8A, for example, illustrates a knit loop. It should be appreciated that FIG. 8A is a view from the skin side, e.g., that the legs of the loops will be in contact with the skin to maximize the surface area of the fabric in contact with the skin and, consequently, to maximum moisture absorption from the skin. FIG. 8B, for example, illustrates a tuck loop. It should be appreciated that FIG. 8B is a view from opposite the skin side. FIG. 8C, for example, illustrates a float loop. It should also be appreciated that FIG. 8C is also a view from opposite the skin side.

Claims

1. A multi-layered knitted fabric, comprising:

a first layer formed of a first yarn;
a second layer formed of a second yarn; and
a third layer formed of a third yarn;
wherein the first yarn includes an evaporative yarn, the second yarn includes a cut resistant yarn, the third yarn includes an evaporative yarn adapted to allow moisture trapped in the second layer to move to the third layer, and the second layer is arranged between the first and third layers; and
wherein the first yarn, the second yarn, and/or the third yarn includes a cut resistant yarn.

2. The multi-layered knitted fabric according to claim 1, wherein the second layer is arranged adjacent the first layer.

3. The multi-layered knitted fabric according to claim 1, wherein the third layer is arranged adjacent the second layer.

4. The multi-layered knitted fabric according to claim 2, wherein the third layer is arranged adjacent the second layer.

5. The multi-layered knitted fabric according to claim 1, wherein the first yarn includes a plurality of an evaporative yarns.

6. The multi-layered knitted fabric according to claim 1, wherein the second yarn includes a plurality of cut resistant yarns.

7. The multi-layered knitted fabric according to claim 1, wherein the third yarn includes a plurality of evaporative yarns.

8. The multi-layered knitted fabric according to claim 1, wherein the multi-layered knit fabric has a density of 100 to 1500 g/m2.

9. The multi-layered knitted fabric according to claim 1, wherein the second layer includes spandex.

10. The multi-layered knitted fabric according to claim 1, wherein the first yarn includes evaporative synthetic polyester and/or nylon yarn with a modified cross-section.

11. The multi-layered knitted fabric according to claim 1, wherein the fabric forms an entire garment.

12. The multi-layered knitted fabric according to claim 11, wherein the garment includes a glove and/or a sleeve.

13. The multi-layered knitted fabric according to claim 1, wherein the fabric is integrated into a garment.

14. The multi-layered knitted fabric according to claim 13, wherein the garment includes a glove and/or a sleeve.

15. The multi-layered knitted fabric according to claim 1, wherein the first layer is adapted to be worn against skin.

16. The multi-layered knitted fabric according to claim 1, wherein the first layer and the second layer include a combination of evaporative, cut resistant, and stretchable synthetic yarns.

17. The multi-layered knitted fabric according to claim 16, wherein the stretchable synthetic yarn includes spandex.

18. The multi-layered knitted fabric according to claim 1, wherein the third layer is adapted to be exposed to an external environment.

19. The multi-layered knitted fabric according to claim 1, wherein the second layer is arranged between the first layer and the third layer.

20. The multi-layered knitted fabric according to claim 1, wherein the second layer includes hydrophobic and hydrophilic channels.

21. The multi-layered knitted fabric according to claim 1, wherein the cut resistant yarn includes tungsten, steel, and/or high-density polyethylene.

22. The multi-layered knitted fabric according to claim 1, wherein the cut resistant yarn includes 100 to 1000 Denier high-density polyethylene yarn and/or 10 to 100 micron tungsten and/or steel monofilament yarn, and wherein the evaporative yarn and/or the absorbent yarn includes 65 Denier/68 filament to 75 Denier/72 draw textured filament polyester and/or nylon yarn and/or 30 Denier/12 filament to 70 Denier/72 filament draw textured filament polyester and/or nylon yarn.

Patent History
Publication number: 20230313426
Type: Application
Filed: Mar 29, 2022
Publication Date: Oct 5, 2023
Inventor: David Chad LAWRENCE (Alpharetta, GA)
Application Number: 17/706,892
Classifications
International Classification: D04B 21/16 (20060101); D04B 21/20 (20060101); A41D 19/00 (20060101); A41D 27/10 (20060101); A41D 31/18 (20060101); A41D 31/24 (20060101);