Three-dimensional, 3D, knitted fabric, and method of manufacturing same

Abstract

A three-dimensional, 3D, knitted fabric is knitted by a double-bed weft-knitting machine. The knitted fabric comprises a top layer, a bottom layer, and an intermediate layer, wherein the top layer and the bottom layer are joined together by cross-yarns constituting the intermediate layer, and wherein at least the top layer comprises two-folded cut-resistant yarns.

Claims

1. A three-dimensional, 3D, weft knitted fabric knitted by a double-bed weft-knitting machine, the knitted three-dimensional fabric comprising a top layer, a bottom layer, and an intermediate layer, wherein the top layer and the bottom layer are joined together by cross-yarns constituting the intermediate layer, wherein at least the top layer comprises two-folded cut-resistant yarns, wherein the two-folded cut-resistant yarns comprise a first yarn and a second yarn, wherein loops of the first yarn alternate with loops of the second yarn, and the loops of the top layer are aligned with loops of the bottom layer, and wherein a linear density of the cross-yarns of the intermediate layer is a minimum five times less than a linear density of the yarns of the top layer, and further wherein one of the two yarns of the second yarn is selected from a group consisting of: basalt fibers, graphene fibers, carbon fibers, steel fiber, and glass fibers.

2. The three-dimensional weft knitted fabric according to claim 1, wherein the cross-yarns are monofilament or multifilament texturized yarns.

3. The three-dimensional weft knitted fabric according to claim 1, wherein a linear density of the cross-yarns of the intermediate layer is in the range of 3.3 to 6 times less the linear density of the yarns of the top layer.

4. The three-dimensional weft knitted fabric according to claim 1, wherein the two-folded cut-resistant yarns have similar linear density, wherein a first yarn is one single yarn or a yarn folded from two yarns of the same type and similar linear density, and the second yarn is folded from two yarns of similar linear density but of different types, and wherein one of the two yarns of the second yarn is basalt.

5. The three-dimensional weft knitted fabric according to claim 1, wherein the bottom layer of the three-dimensional weft knitted fabric comprises least one of: PES, PP, FRCV, and natural fiber yarns.

6. The three-dimensional weft knitted fabric according to claim 1, wherein the cross-yarns of the intermediate layer is made from impact absorbing elastic texturized yarns.

7. The three-dimensional weft knitted fabric according to claim 4, wherein the first yarn and the second yarn are folded in an S-direction with a twist in the range of 80 m.sup.−1 to 120 m.sup.−1.

8. The three-dimensional weft knitted fabric according to claim 7, wherein the bottom layer is identical to the top layer.

9. The three-dimensional weft knitted fabric according to claim 1, wherein a tightness factor of the top layer is in the range of 2-18 wherein the tightness $\mathrm{TF}=\left(\sqrt{\frac{\mathrm{tex}}{l}}\right)\mathrm{first}\mathrm{yarn}\pm \left(\sqrt{\frac{\mathrm{tex}}{l}}\right)\mathrm{second}\mathrm{yarn},$ wherein l is the loop length, measured in mm, and tex is the yarn linear density in grams per kilometer.

10. A safety clothing comprising the three-dimensional weft knitted fabric according to claim 1.

11. The safety clothing according to claim 10, comprising at least two parts joined by lockstitch or chain stitch, wherein at least one of said at least two parts is made from the three-dimensional weft knitted fabric.

12. The safety clothing according to claim 11, wherein at least one of said at least two parts of the safety clothing comprises at least two layers of the three-dimensional weft knitted fabric.

13. The safety clothing according to claim 10, wherein at least one surface of the three-dimensional weft knitted fabric is laminated with a liquid proof material.

14. A composite material comprising the three-dimensional weft knitted fabric according to claim 1, wherein the three-dimensional weft knitted fabric is embedded in one of or a combination of epoxy, vinyl ester, a polyester resin, or rubber.

15. A method for manufacturing a three-dimensional weft knitted fabric, the three-dimensional weft knitted fabric being manufactured via of a double-bed weft-knitting machine, wherein the method comprises simultaneously knitting a top layer, a bottom layer and an intermediate layer for providing a connection between the top layer and the bottom layer, the intermediate layer comprising cross-yarn configured for providing a resilient connection between the top layer and the bottom layer, wherein the method further comprises knitting the top layer from two-folded cut-resistant yarns, wherein the two-folded cut-resistant yarns comprise a first yarn and a second yarn, wherein loops of the first yarn alternate with loops of the second yarn, and the loops of the top layer are aligned with loops of the bottom layer, and wherein a linear density of the cross-yarns of the intermediate layer is a minimum five times less than a linear density of the yarns of the top layer, and further wherein one of the two yarns of the second yarn is selected from a group consisting of: basalt fibers, graphene fibers, carbon fibers, steel fiber, and glass fibers.

16. The method according to claim 15, further comprising knitting the bottom layer from at least one of PES, PP, FRCV and natural fiber yarns.

17. The method according to claim 15, further comprising knitting the bottom layer from yarns of the same type as in the top layer.

18. The method according to claim 15, wherein the two-folded cut-resistant yarns comprise basalt fibers.

19. A method for manufacturing a clothing comprising the three-dimensional weft knitted fabric manufactured via the method according to claim 15, the method comprising joining all parts for the clothing by lockstitch or chain stitch, and orienting the top layer of the three-dimensional weft knitted fabric such that it forms an outside of the clothing.

20. The method according to claim 18, wherein the clothing is a human personal protective clothing selected from a group consisting of: a work glove, a T-shirt, a waistcoat, an apron, an oversleeve, a collar, a jacket, shorts, trousers, a headgear, and a suit.

21. The method according to claim 18, further comprising providing at least two layers of the three-dimensional weft knitted fabric to form at least one of said at least two parts of the human personal protective clothing.

22. The method of manufacturing a composite material, further comprising embedding the three-dimensional weft knitted fabric according to claim 1, in one of or a combination of epoxy, vinyl ester, a polyester resin, and rubber.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The proposed three-dimensional (3D) knitted fabric is illustrated in the drawings, where:

(2) FIG. 1 is a cross-section view of three-dimensional (3D) knitted fabric;

(3) FIG. 2 is a 3D partial cross-sectional view of three-dimensional (3D) knitted fabric;

(4) FIG. 3 is a scheme of the knitting cycle of production of three-dimensional (3D) knitted fabric;

(5) FIG. 4 is a view of a stitched glove from the palm side and the back side;

(6) FIG. 5 is a view of a T-shirt;

(7) FIG. 6 is a view of a waistcoat;

(8) FIG. 7 is a view of an apron;

(9) FIG. 8 is a view of an oversleeve from the side and front;

(10) FIG. 9 is a view of a collar from the front and back;

(11) FIG. 10 is a view of a jacket from the front and back;

(12) FIG. 11 is a view of shorts from the front and side;

(13) FIG. 12 is a view of trousers from the front and side;

(14) FIG. 13a is a cross-sectional view of two layers of fabrics according to the invention arranged on top of each other;

(15) FIG. 13b is a cross-sectional view of an alternative embodiment of the double or two-layered fabric shown in FIG. 13a;

(16) FIG. 14a is a cross-sectional view of a fabric according to the invention, wherein the fabric is laminated with a liquid proof material; and

(17) FIG. 14b is a cross-sectional view of a fabric according to the invention, wherein the fabric is laminated with a liquid proof material on one side only.

DETAILED DESCRIPTION OF THE DRAWINGS

(18) In the figures, same or corresponding elements are indicated by same reference numerals.

(19) A person skilled in the art will understand that the figures are just principle drawings. The relative proportions between individual elements may also be strongly distorted.

(20) In the figures, the three-dimensional (3D) knitted fabric according to the present invention comprises a top layer 1, a bottom layer 2, and an intermediate layer 3.

(21) As best seen in FIG. 1 and FIG. 2, the top layer 1 and bottom layer 2 are joined together by cross-yarns 7. These cross-yarns 7 constitute the intermediate layer 3. Preferably, the cross-yarns 7 are monofilament or multifilament texturized yarns 7, which provide the required three-dimensional structure of the fabric according to the present invention.

(22) Preferably, the cross-yarns 7 comprise impact absorbing elastic texturized PES, PA yarns 7 or PES or PA yarns with elastane or Spandex.

(23) A special combination of loops 8 allows simultaneous production of the two separate layers 1 and 2 of different functions, as will be explained below.

(24) In a clothing comprising the fabric according to the present invention, the top layer 1 is oriented outwards and protects a user from cutting. The bottom layer 2 is oriented inwards, i.e. towards a human skin, and ensures comfort.

(25) The three-dimensional (3D) knitted fabric according to the present invention is knitted by means of a double-bed weft-knitting machine.

(26) The orientation of the fibres in the fabric increases the cut resistance. The cross-yarns 7 are configured for absorbing impact between the separate layers (i.e. the top layer 1 and bottom layer 2). Depending on the type of cross-yarns 7 utilized in the fabric, the fabric may provide a good air permeability, and can allow the transportation of moisture from the intermediate layer 3 outwards.

(27) The top layer 1 of three-dimensional (3D) knitted fabric consists of two-folded cut-resistant yarns 4, 5 of similar linear density.

(28) A first yarn 4 (shown grey in FIGS. 1, 2 and 3) of the two-folded cut-resistant yarns 4, 5 in the top layer 1, may consist of one single yarn or it may be folded from two yarns of the same type and similar linear density, such as for example HPPE or Kevlar®, and a second yarn 5 (shown black in FIGS. 1, 2 and 3) of the two-folded cut-resistant yarns 4, 5 in the first layer is folded from two yarns of similar linear density, but of different type. The second yarn 5 of the top layer may for example be a combination of HPPE and basalt or a combination of Kevlar® and basalt. Alternatively, the second yarn 5 of the top layer 1 may for example, but not limited to, be HPPE comprising graphene or Kevlar® comprising graphene.

(29) The bottom layer 2 of three-dimensional (3D) knitted fabric is typically oriented inwards in a clothing comprising the fabric. In order to provide comfort against the skin of a wearer of the clothing, the bottom layer 2 may comprise PES, PP or natural fibre yarns 6 such as for example cotton or wool.

(30) Depending on the fibrous composition of the first layer 1 and the second layer 2 or the fabric according to the present invention, as well as their structure, pattern, etc. and/or on the linear density of the joining cross-yarns, the loop length(s) L.sub.4, L.sub.5, L.sub.6 and/or the tightness factor TF, the fabric may have different characteristics. Such different characteristics may be utilized in fabrics of the present invention utilized in various parts of for example a safety clothing, wherein said parts may have different thicknesses.

(31) Thus, in addition to high cut resistance and air permeability, the fabric according to the invention may also ensure tactile sensitivity, accuracy of the performed movements and high flexibility. The thickness of the fabric also depends on the class of a double-bed weft-knitting machine, as will be known to a person skilled in the art.

(32) To produce the 3D knitted fabric, a certain knitting cycle and/or pattern is based on using the features of double-bed weft-knitting machines.

(33) The fabric according to the present invention is formed by using the yarn-feeding schemes to the needle-systems I, II, III, IV and V shown in FIG. 3.

(34) First of all, the cross-yarns 7 are fed to the knitting machine and, by working with the needle systems I and II, the connecting layer 3 is produced. Thereafter, the needle systems III, IV and V, which were not used in the earlier stage(s), are loaded with the yarns 4, 5 for the top layer 1 and the yarn 6 for the bottom layer, and the top layer 1 and the bottom layer 2 are produced simultaneously. The characteristic features of the 3D fabric thus produced, may be adapted according to the needs by merely selecting appropriate functional yarns 4, 5; 6; 7.

(35) To produce three-dimensional (3D) knitted fabric for safety clothing, the knitting cycle includes the following actions (see FIG. 3): I, II—to knit the intermediate layer 3 of the cross-yarns 7 connecting the top layer 1 and the bottom layer 2, impact absorbing elastic texturized PES, PA yarns 7, or PES or PA yarns in combination with elastane or Spandex ranging from 3.3 to 6 tex, are used respectively.

(36) A person skilled in the art will know that tex is a unit of textile measurement, and that 1 tex=1 g/km=1 mg/m. Textile fibers, threads, yarns, and fabrics are measured in a multiplicity of units.

(37) Extensive tests have surprisingly shown that the absolutely best cut resistance of the fabric is achieved when the linear density of the cross-yarns 7 of the intermediate layer 3 is minimum five times less than the linear density of the yarns 4, 5 of the top layer 1.

(38) Said extensive test has also surprisingly shown that a very high cut and punch resistance of the fabric is achieved when the tightness factor TF of the top layer 1 is in the range of 2-18. III—to knit the top layer 1, a first cut-resistant yarn 4 (shown grey in FIGS. 1, 2 and 3) of the two-folded cut-resistant yarns 4, 5, is used, wherein the yarn 4 comprises one single yarn or the yarn 4 is folded from two yarns of the same type and similar linear density. The first yarn 4, independently of being one single yarn or two yarns of the same type and similar density, may be made for example from HPPE or Kevlar®. In the case the first yarn 4 comprises two yarns, the linear density of separate yarns 4 may for example be 25 tex, and the total linear density of the yarn is up to 50 tex, and it should be close to the linear density of the other yarn 5 of the two-folded cut-resistant yarn 4, 5. In the case of the first yarn 4 comprising only a single yarn, the linear density may for example be up to 50 tex. Typically, the loop length L.sub.5 may range from about 0.1 cm to about 0.6 cm. A knitted fabric density of machine direction and transverse direction is in the range of 5 to 20 loops/cm. IV—to knit the bottom layer 2, comfortable PES, PP or natural fibre yarns 6, such as for example cotton or wool, are used, which may be spun yarn or texturized, multifilament yarns ranging from 3.3 tex to 40 tex. The loop length L.sub.6 may range from is e.g. about 0.1 cm to about 0.6 cm. V—to further knit the top layer 1, a cut-resistant yarn 5 is used folded from two yarns of similar linear density but different type, for example by combining HPPE with basalt or combining Kevlar® with basalt, or for example HPPE or PA, comprising graphene, or Kevlar® comprising graphene. The total linear density of the yarn is up to 50 tex, and it should be close to the linear density of the first yarn 4 of the top layer 1; the loop length L.sub.5 may range from e.g. about 0.1 cm to about 0.6 cm.

(39) In what follows, examples of a three-dimensional fabric according to the present invention will be discussed.

Example 1

(40) The intermediate layer 3 of the cross-yarns 7 of a three-dimensional (3D) thin knitted fabric comprises impact absorbing texturized PA yarns 7 of 3.3×2 tex.

(41) The top layer 1 comprises a first cut-resistant yarn 4 made from two HPPE yarns of 22.2 tex folded in S-direction with a twist of 100 m.sup.−1 (i.e. a twist of 100 per one meter). The twist per meter of a yarn is dependent on the yarn count.

(42) The total linear density of the first cut-resistant yarn 4 is 44.4 tex; and the loop length L.sub.4 is 0.4 cm.

(43) The top layer 1 further comprises a second cut-resistant yarn 5 folded in S-direction with a twist of 100 m.sup.−1. The second yarn 5 is made from two yarns of 22.2 tex with the same linear density but of different types. The two yarns were made from HPPE and basalt.

(44) The total linear density of the second cut-resistant yarn 5 is 44.4 tex; and the loop length L.sub.5 is 0.4 cm.

(45) The texturized PA cross-yarns 7 of the intermediate layer 3 have a linear density being seven times less than the linear density of the yarns 4, 5 of the top layer 1.

(46) The tightness factor TF of the top layer 1 is 15.1. The bottom layer 2 consists of comfortable texturized PES (8.3 tex, 144 fil.); and the loop length L.sub.6 of this yarn 6 is 0.31 cm.

(47) The tightness factor TF of the bottom layer 2 is 9.3.

(48) The three-dimensional fabric made according to this first example, showed that the cut resistance index is more than twice the cut resistance index 20 of level 5. The result was obtained in compliance with the European standard EN 388.

Example 2

(49) Example 2 has many similarities with example 1 above.

(50) The intermediate layer 3 of the cross-yarns 7 of a three-dimensional (3D) thick knitted fabric comprises impact absorbing monofilament PA yarns 7 of 5.6 tex.

(51) The top layer 1 comprises a first cut-resistant yarn 4 made from two HPPE yarns of 22.2 tex folded in S-direction with a twist of 100 m.sup.−1 (i.e. a twist of 100 per one meter). The twist per meter of a yarn is dependent on the yarn count. By the term yarn count is meant weight per unit length if the yarn or the length per unit weight.

(52) The total linear density of the first cut-resistant yarn 4 is 44.4 tex; and the loop length L.sub.4 is 0.4 cm.

(53) The top layer 1 further comprises a second cut-resistant yarn 5 folded in S-direction, with a twist of 100 m.sup.−1. The second cut-resistant yarn 5 is made from two yarns of 22.2 tex with the same linear density but of different types. The two yarns were made from HPPE and basalt.

(54) The total linear density of the second cut-resistant yarn 5 is 44.4 tex; and the loop length L.sub.5 is 0.4 cm.

(55) The monofilament PA yarns 7 of the intermediate layer 3 have a linear density being seven times less than the linear density of the yarns 4, 5 of the top layer 1.

(56) The tightness factor TF of the top layer 1 is 15.1. The bottom layer 2 consists of comfortable texturized PES (8.3 tex, 144 fil.); and the loop length L.sub.6 of this yarn 6 is 0.31 cm.

(57) The tightness factor TF of the bottom layer 2 is 9.3.

(58) The three-dimensional, 3D, fabric made according to this second example, showed that the cut resistance index is more than twice the cut resistance index 20 of level 5.

(59) The result was obtained in compliance with the European standard EN 388.

Example 3

(60) The intermediate layer 3 of the cross-yarns 7 of a three-dimensional (3D) thin knitted fabric comprises impact absorbing texturized FRPES yarns 7 of 5.6 tex.

(61) The top layer 1 comprises a first cut-resistant yarn 4 made from two Kevlar® yarns of 22.2 tex folded in S-direction with a twist of 100 m.sup.−1 (i.e. a twist of 100 per one meter).

(62) The total linear density of the first cut-resistant yarn 4 is 44.4 tex; and the loop length L.sub.4 is 0.4 cm.

(63) The top layer 1 further comprises a second cut-resistant yarn 5 folded in S-direction with a twist of 100 m.sup.−1. The second cut-resistant yarn 5 is made from two yarns of 22.2 tex with the same linear density but of different types. The two yarns were made from Kevlar® and basalt.

(64) The total linear density of the second cut-resistant yarn 5 is 44.4 tex; and the loop length L.sub.5 is 0.4 cm.

(65) The texturized FRPES, i.e. flame-retardant polyester (fiber), yarns 7 of the intermediate layer 3 have a linear density being eight times less than the linear density of the yarns 4, 5 of the top layer 1.

(66) The tightness factor TF of the top layer 1 is 15.1. The bottom layer 2 consists of comfortable texturized FRCV yarn 6 of 8.3 tex; and the loop length L.sub.6 of this yarn 6 is 0.31 cm.

(67) The tightness factor TF of the bottom layer 2 is 9.3.

(68) The three-dimensional, 3D, fabric made according to this third example showed that the cut resistance index is more than twice the cut resistance index 20 of level 5. The result was obtained in compliance with the European standard EN 388.

Example 4

(69) The intermediate layer 3 of the cross-yarns 7 of a three-dimensional (3D) thick knitted fabric comprises impact absorbing monofilament FRPES yarns 7 of 5.6 tex.

(70) The top layer 1 comprises a first cut-resistant yarn 4 made from two Kevlar yarns of 22.2 tex folded in S-direction with a twist of 100 m.sup.−1 (i.e. a twist of 100 per one meter).

(71) The total linear density of the first cut-resistant yarn 4 is 44.4 tex; and the loop length L.sub.4 is 0.4 cm.

(72) The top layer 1 further comprises a second cut-resistant yarn 5 folded in S-direction with a twist of 100 m.sup.−1. The second cut-resistant yarn 5 is made from two yarns of 22.2 tex with the same linear density but of different types. The two yarns were made from Kevlar® and basalt.

(73) The total linear density of the second cut-resistant yarn 5 is 44.4 tex; and the loop length L.sub.5 is 0.4 cm.

(74) The monofilament FRPES yarns 7 of the intermediate layer 3 have a linear density being eight times less than the linear density of the yarns 4, 5 of the top layer 1.

(75) The tightness factor TF of the top layer 1 is 15.1. The bottom layer 2 consists of comfortable texturized FRCV yarn 6 of 8.3 tex; and the loop length L.sub.6 of this yarn 6 is 0.31 cm.

(76) The tightness factor TF of the bottom layer 2 is 9.3.

(77) The three-dimensional, 3D, fabric made according to this fourth example showed that the blade cut resistance index is more than twice the cut resistance index 20 of level 5. The result was obtained in compliance with the European standard EN 388: 2003 Clause 6.2.

Example 5

(78) The intermediate layer 3 of the cross-yarns 7 of a three-dimensional (3D) thin knitted fabric comprises impact absorbing textured PA yarns 7 of 3.3×2 tex.

(79) The top layer 1 and the bottom layer 2 comprise a first cut-resistant yarn 4 made from two HPPE yarns of 22.2 tex folded in S-direction with a twist of 100 m.sup.−1. The twist per meter of a yarn is dependent on the yarn count.

(80) The total linear density of the first cut-resistant yarn 4 is 44.4 tex; and the loop length L.sub.4 is 0.4 cm.

(81) The top layer 1 and the bottom layer 2 further comprise a second cut-resistant yarn 5 folded in S-direction with a twist of 100 m.sup.−1. The second cut-resistant yarn 5 is made from two yarns of 22.2 tex with same linear density but of different types. The two yarns were made from HPPE and basalt.

(82) The total linear density of the second cut-resistant yarn 5 is 44.4 tex; and the loop length L.sub.5 is 0.4 cm.

(83) The texturized PA yarns 7 of the intermediate layer 3 have a linear density being seven times less than the linear density of the yarns 4, 5 of the top layer 1.

(84) The tightness factor TF of the top layer 1 and bottom layer 2 is 15.1.

(85) The three-dimensional, 3D, fabric made according to this fifth example showed that the blade cut resistance index is more than four times the cut resistance index 20 of level 5. The result was obtained in compliance with the European standard EN 388: 2003 Clause 6.2.

Example 6

(86) The intermediate layer 3 of the cross-yarns 7 of a three-dimensional (3D) thick knitted fabric comprises impact absorbing monofilament PA yarns 7 of 5.6 tex.

(87) The top layer 1 and the bottom layer 2 comprise a first cut-resistant yarn 4 made from two HPPE yarns of 22.2 tex folded in S-direction with a twist of 100 m.sup.−1. The twist per meter of a yarn is dependent on the yarn count.

(88) The total linear density of the first cut-resistant yarn 4 is 44.4 tex; and the loop length L.sub.4 is 0.4 cm.

(89) The top layer 1 and the bottom layer 2 further comprise a second cut-resistant yarn 5 folded in S-direction with a twist of 100 m.sup.−1. The second cut-resistant yarn 5 is made from two yarns of 22.2 tex with same linear density but of different types. The two yarns were made from HPPE and basalt.

(90) The total linear density of the second cut-resistant yarn 5 is 44.4 tex; and the loop length L.sub.5 is 0.4 cm.

(91) The monofilament PA yarns 7 of the intermediate layer 3 have a linear density being seven times less than the linear density of the yarns 4, 5 of the top layer 1.

(92) The tightness factor TF of the top layer 1 and bottom layer 2 is 15.1.

(93) The three-dimensional, 3D, fabric made according to this sixth example showed that the cut resistance index is more than four times the cut resistance index 20 of level 5. The result was obtained in compliance with the European standard EN 388 Clause 6.2.

Example 7

(94) The intermediate layer 3 of the cross-yarns 7 of a three-dimensional (3D) thin knitted fabric comprises impact absorbing texturized PA yarns 7 of 3.3×2 tex.

(95) The top layer 1 comprises a first cut-resistant yarn 4 made from one single HPPE yarn of 44.4 tex.

(96) The total linear density of the first cut resistant yarn 4 is thus 44.4 tex; and the loop length L.sub.4 is 0.4 cm.

(97) The top layer 1 further comprises a second cut-resistant yarn 5 folded in S-direction with a twist of 100 m.sup.−1. The second yarn 5 is made from two yarns of 22.2 tex with the same linear density but of different types. The two yarns were made from HPPE and basalt.

(98) The total linear density of the second cut-resistant yarn 5 is 44.4 tex; and the loop length L.sub.5 is 0.4 cm.

(99) The texturized PA cross-yarns 7 of the intermediate layer 3 have a linear density being seven times less than the linear density of the yarns 4, 5 of the top layer 1.

(100) The tightness factor TF of the top layer 1 is 15.1. The bottom layer 2 consists of comfortable texturized PES (8.3 tex, 144 fil.); and the loop length L.sub.6 of this yarn 6 is 0.31 cm.

(101) The tightness factor TF of the bottom layer 2 is 9.3.

(102) The three-dimensional fabric made according to this seventh example, showed that the cut resistance index is more than twice the cut resistance index 20 of level 5. The result was obtained in compliance with the European standard EN 388.

(103) The three-dimensional, 3D, fabric according to the present invention may be used at least as one portion of a safety clothing.

(104) FIGS. 4 to 12 show various types of such a safety clothing.

(105) FIG. 4 shows a work glove according to the present invention comprising a palm part 9, a back part 10, finger parts 11, and a cuff part 12. In FIG. 4, both the palm part 9 and the back part 10 are made from the three-dimensional knitted fabric (indicated “folded up”) according to the present invention.

(106) FIG. 5 shows a T-shirt according to the present invention comprising a front part 13 and a sleeve 14. In the embodiment shown, the front part is made from the three-dimensional knitted fabric (indicated “folded up”) according to the present invention.

(107) FIG. 6 shows a waistcoat according to the present invention comprising a front part 15 made from the three-dimensional knitted fabric (indicated “folded up”) according to the present invention.

(108) FIG. 7 shows an apron 16 according to the present invention made from the three-dimensional knitted fabric (indicated “folded up”) according to the present invention.

(109) FIG. 8 shows an oversleeve according to the present invention comprising an elbow part 17, top parts 18, 19 and a bottom part 20. In the embodiment shown, the top part 19 is made from the three-dimensional knitted fabric (indicated “folded up”) according to the present invention.

(110) FIG. 9 shows a collar according to the present invention comprising a front part 21 and a back part 22. In the embodiment shown, the front part 21 is made from the three-dimensional knitted fabric (indicated “folded up”) according to the present invention.

(111) FIG. 10 shows a jacket according to the present invention comprising a front part 23, a back part 24, a collar part 25, and sleeve parts 26. In the embodiment shown, the front part 23 and the back part 24 are made from the three-dimensional knitted fabric (indicated “folded up”) according to the present invention. In another embodiment, at least a portion of the sleeve parts 26 may also be made from the three-dimensional knitted fabric according to the present invention.

(112) FIG. 11 shows a pair of shorts comprising a front part 27, a back part 28, and a waistband 29, wherein the front part 27 is made from the three-dimensional knitted fabric according to the present invention.

(113) FIG. 12 shows a pair of trousers comprising a front part 30, a back part 31 and a waistband 32, wherein the front part 30 is made from the three-dimensional knitted fabric according to the present invention.

(114) It should be noted that in the clothes shown in FIGS. 4 to 12, only portions of the various parts shown may comprise the three-dimensional knitted fabric according to the present invention. Further, other parts of the clothes than those shown and described above, may comprise the three-dimensional knitted fabric according to the present invention. Thus, the three-dimensional (3D) knitted fabric used for the clothing allows protecting desired parts of the human body being vulnerable for sharp objects.

(115) FIG. 13a shows a basic cross-sectional view of a portion of two fabrics according to the invention, where one fabric is arranged on top of the other to form a ply of fabrics. At least a portion of the periphery of the two fabrics may be connected to each other by any suitable means, such as for example an adhesive, stitches etc. In one embodiment, the two layers of fabric is a quilted fabric. In another embodiment, the two fabrics may in a position of use be arranged as “free hanging” independent layers. Such free hanging independent layers of fabrics may be connected to each other in a top portion only, or to a common connection means (not shown) arranged in a top portion of a protective clothing. In FIG. 13a a bottom layer 2 of a first or top fabric TFA abuts a top layer 1 of a second or bottom fabric BF according to the invention. In the embodiment shown, the bottom layer 2 of the first or top fabric TFA is identical to the top layer 1 of the top fabric TFA, i.e. it comprises two-folded cut-resistant yarns 4, 5. In such an embodiment, the two-layered or ply of fabric QF comprises three layers of cut-resistant yarns 4,5. In another embodiment (not shown), also the bottom layer 2 of the second fabric BF comprises two-folded cut-resistant yarns 4, 5. In such an embodiment, the two-layered fabric QF comprises four layers of cut-resistant yarns 4,5.

(116) In still another embodiment, only the top layers 1 of the first fabric TFA and second fabric BF comprise cut-resistant yarns 4, 5. In such an embodiment the two-layered fabric QF comprises only two layers of cut-resistant yarns 4,5.

(117) The so-called machine direction of one of the two fabrics TFA, BF is preferably arranged non-parallel, for example but not limited to, perpendicular, with a machine direction of the other of the two fabrics TFA, BF. As mentioned above, the two-layered fabric QF may be fixedly connected to each other at least at a periphery portion thereof, or the two fabrics TFA, BF may be arranged as “free hanging” independent layers of fabrics.

(118) FIG. 13b shows an alternative to the embodiments discussed in relation to FIG. 13a. In FIG. 13b, the top fabric TFA is inverted, such that the cut-resistant top layer 1 of the top fabric TFA abuts against the cut-resistant top layer 1 of the bottom fabric BF. In the embodiment shown in FIG. 13b, the two-layered fabric QF outermost layers 2 of the top fabric TFA and the bottom or lowermost fabric BF, may consist of fibers from is at least one of: PES, PP, FRCV, PA and natural fibre yarns such as for example cotton or wool. In the embodiment shown in FIG. 13b wherein the top fabric TFA has been inverted, the inner layer 1 previously denoted top layer 1 or cut-resistant top layer 1, may have a tightness factor TF up to two times that of the outermost layer 2. The same applies for the bottom fabric BF; the tightness factor TF of the top or inner layer 1, may have a tightness factor TF up to two times that of the lowermost layer 2.

(119) For example, the outermost layer 2 of the top fabric TFA shown in FIG. 13b may comprise abrasion resistant yarns. The bottom or lowermost layer 2 of the bottom fabric BF may include a yarn that increases comfort, and this layer could be used in contact with the skin of a user. In such case the protective layers 1 of cut-resistant yarns of both the top fabric TFA and the bottom fabric BF are “enclosed” inside the two-layered fabric TFA, BF.

(120) In FIGS. 13a and 13b, the two-layered fabric QF comprises two layers of fabric TFA, BF. However, in an alternative embodiment (not shown), the two-layered fabric may comprise more than two fabrics, for example three or four, layers of fabric arranged in a similar way as discussed above. In an embodiment with three layers of fabric, the top fabric TFA of the type shown in FIG. 13a, could for example be arranged between the top fabric TFA and the bottom fabric BF shown in FIG. 13b.

(121) FIG. 14a shows a fabric according to an embodiment of the invention, wherein the fabric is laminated with a liquid proof material. In the embodiment shown, both the top layer 1 and the bottom layer 2 are provided with the liquid proof material LF. In one embodiment, only the top layer 1 comprises two-folded cut-resistant yarns 4, 5. Such an embodiment is shown in FIG. 14b.

(122) It should be noted that one or both sides of the outer surface the two-layered fabric QF shown in FIGS. 13a and 13b, could also be laminated with a liquid proof material LF.

(123) In FIGS. 13a, 13b, 14a and 14b, the hatching of the various layers 1, 2, 3 of the fabric is for illustrative purposes only.

(124) A three-dimensional, 3D, knitted fabric according to the present invention shown in FIGS. 4-12, 14a, and 14b will typically have a surface density in the range from 150 to 800 g/m2 and puncture resistance from 180N to 750N.

(125) Tests of the fabric executed according to EN 388: 2003 surprisingly shows extremely high resistance against abrasion, cut, tear, and puncture. Other known materials may achieve same results of one or two of the features, but the applicant has not found any material having similar test results for all four of said features. The two-layered is fabric according to the invention also fulfils the requirement of British Police Standard “HOSDB Slash Resistance Standard UK Police (2006) Publication 48/05”.

(126) The application of double weft knitting allows, due to weft deformations, comfortable use of clothing made from or comprising the fabric according to the present invention because the produced clothing will be flexible, easy to put on and will not provide any significant restriction of movements of the wearer.

(127) The structure of three-dimensional (3D) knitted fabric according to the present invention allows additional extension of clothing functionality by applying simple structural-technological means by stitching, gluing, welding, or otherwise fixing parts of fabric of different purposes to the clothing. For example, in order to increase the level of abrasion resistance of the clothing, it is possible to stitch elements of abrasion resistant fabric preserving good air-permeability, flexibility, comfort, and very high cut resistance.

(128) From the above it should be clear that the present invention provides a fabric maintaining desired comfort, reducing manufacturing costs, extending functionality, and providing a cut resistance index of more than 20, which is the highest resistance to cutting forces according to EN 388: 2003 Clause 6.2.

(129) Embodiments of the fabric disclosed herein is therefore suitable for use in human personal protective equipment, such as clothing e.g. for gas and oil industry, chemical industry, construction industry and other branches of industry, wherein the cut and/or puncture resistance is of importance. The three-dimensional (3D) knitted fabrics may be used in designing and production of clothing, or as a fabric for use in furniture subject to high wear or even vandalism, such as a seating for public transportation, or as body armour for police forces or military personnel or security guards or special forces, for example.

(130) The fabric is also suitable for use as reinforcement in a composite material.

(131) It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims. In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. Use of the verb “comprise” and its conjugations does not exclude the presence is of elements or steps other than those stated in a claim. The article “a” or “an” preceding an element does not exclude the presence of a plurality of such elements.

(132) The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.