ANTIMICROBIAL MULTILAYER KNIT FABRIC HAVING AIR LAYER, AND MANUFACTURING METHOD THEREFOR

Abstract

The present invention relates to a multilayer knit fabric and a manufacturing method for the same and, more particularly, to an antimicrobial multilayer knit fabric having an air layer and a manufacturing method for the same. The multilayer knit fabric of the present invention comprises an upper knit fabric, a lower knit fabric, and a vertical knit fabric including a monofilament yarn, where the upper and lower knit fabrics are spaced apart from each other by the vertical knit fabric to form an air layer inside.

Claims

1. A multilayer knit fabric comprising an upper knit fabric; a lower knit fabric; and a vertical knit fabric comprising a monofilament yarn, wherein the upper and lower knit fabrics are spaced apart from each other by the vertical knit fabric to form an air layer inside.

2. The multilayer knit fabric according to claim 1, wherein the multilayer knit fabric is an antimicrobial knit fabric.

3. The multilayer knit fabric according to claim 1, wherein the upper knit fabric is a non-antimicrobial knit fabric.

4. The multilayer knit fabric according to claim 1, wherein the upper knit fabric is a yarn dyed knit fabric.

5. The multilayer knit fabric according to claim 1, wherein the upper knit fabric comprises at least one fiber selected from the group consisting of polyester, nylon, and spandex, the fiber being a 20-50 D fiber.

6. The multilayer knit fabric according to claim 1, wherein the lower knit fabric is an antimicrobial knit fabric.

7. The multilayer knit fabric according to claim 1, wherein the lower knit fabric is an antimicrobial and electrically conductive knit fabric.

8. The multilayer knit fabric according to claim 1, wherein the lower knit fabric is made by knitting using a fiber containing a copper component and a fiber not containing a copper component.

9. The multilayer knit fabric according to claim 8, wherein the fiber containing a copper component is a conductive fiber having a coating of the copper component on the surface of a nylon fiber.

10. The multilayer knit fabric according to claim 1, wherein the monofilament yarn is at least one selected from the group consisting of a polypropylene monofilament yarn, a nylon monofilament yarn, and a polyester monofilament yarn.

11. The multilayer knit fabric according to claim 10, wherein the monofilament yarn has a thickness of 20-50 D.

12. The multilayer knit fabric according to claim 10, wherein the monofilament yarn is knitted together with a fiber containing a copper component.

13. The multilayer knit fabric according to claim 1, wherein the multilayer knit fabric has the upper and lower knit fabrics spaced at least 1.0 mm apart by the vertical knit fabric.

14. A method for manufacturing the multilayer knit fabric according to claim 1, the method comprising supplying a fiber containing a copper component and a fiber comprising a monofilament yarn to a double-sided circular knitting machine having a 18 to 30 gauge with a loop length of 4 to 20 cm through 80 to 150 feeders.

15. An antimicrobial or antistatic clothing comprising the multilayer knit fabric according to claim 1.

16. A water-absorbing fabric comprising the multilayer knit fabric according to claim 1.

17. An incontinence pad comprising a water-absorbing fabric comprising the multilayer knit fabric according to claim 1.

Description

BEST MODES FOR CARRYING OUT THE INVENTION

[0039] Hereinafter, the present invention will be described in detail with reference to examples, which are not intended to limit the present invention, but to illustrate the present invention.

EXAMPLES

[0040] Preparation of Yarns

[0041] Kolon Glotech fiber was used as a non-conductive fiber containing copper. A polyester yarn was 50 denier, and a spandex yarn was a thin yarn of 30 denier.

[0042] A conductive nylon fiber containing copper was prepared according to the example of Korean Patent No. 1925070. After a nylon fiber of about 70 denier was added to a reaction tank, the liquor ratio was adjusted to 1:15-20, and 3 to 5 g/L of a deoiling agent was added to treat the nylon fiber for 40 minutes at 60° C. The suspended substances produced by the deoiling agent were removed by application of water. To the reaction tank were added 2-3% o.w.f of levulinic acid, 0.1-0.5% o.w.f of sodium lauryl sulfate, 0.1-0.3% o.w.f of polyethylene glycol, 8-10% o.w.f of sodium thiosulfate, and 0.2% o.w.f of EDTA, 10-20% o.w.f of copper sulfate. After agitation for about 10 minutes, the pH was maintained in the range of 4 to 5 and the temperature was raised to 60° C. at a rate of 1° C./min. The reaction was activated for 60 minutes at 60° C., and 0.3% o.w.f of sodium hypophosphate was added to cause reduction and precipitation for 20 minutes at 60° C. Unreacted substances were removed at the pH of up to 7. 0.3% o.w.f of magnesium hydroxide was added at the pH 7 to treat the nylon fiber for 20 minutes at 40° C. After removal of the residual sulfur, it was confirmed that the resultant conductive nylon fiber had a specific resistance of 10.sup.2 Ωcm.

Example 1

[0043] A double-sided circular knitting machine was provided with feeders for supplying polyester, nylon, and spandex yarns for an upper knit fabric; feeders for supplying a conductive fiber containing a copper component, a non-conductive fiber containing a copper component, a nylon 66 yarn and a spandex yarn for a lower knit fabric; and feeders for supplying a polyester monofilament yarn and a non-conductive fiber containing a copper component for a vertical knit fabric. At the feeders provided for the upper knit fabric, the yarn dyed polyester had a thickness of 75 D, the nylon 50 D, and the spandex 20 D. At the feeders provided for the lower knit fabric, the conductive fiber containing a copper component was 70 D in thickness, the non-conductive fiber containing a copper component 70 D, the nylon yarn 70 D, and the spandex yarn 20 D. At the feeders for the vertical knit fabric, the polyester monofilament yarn had a thickness of 40 D, and the non-conductive fiber containing a copper component 70 D.

[0044] The upper knit fabric comprised 15 wt. % of polyester, 10 wt. % of nylon, and 5 wt. % of spandex; the lower knit fabric was composed of 5 wt. % of a conductive fiber containing a copper component, 15 wt. % of a non-conductive fiber containing a copper component, 20 wt. % of nylon, and 5 wt. % of spandex; and the vertical knit fabric comprised 20 wt. % of a monofilament yarn and 5 wt. % of a non-conductive fiber containing a copper component.

[0045] The multilayer knit fabric thus manufactured was completed through a refining process, and the upper and lower knit fabrics were spaced about 2 mm apart from each other.

Example 2

[0046] The procedures were performed in the same manner as described in Example 1, excepting that the vertical knit fabric used the polyester monofilament yarn alone, not in combination with the non-conductive fiber containing a copper component, while the amount of the polyester monofilament yarn was increased to 25 wt. %.

Example 3

[0047] The procedures were performed in the same manner as described in Example 1, excepting that the vertical knit fabric used a nylon 6 monofilament yarn in place of the polyester monofilament yarn.

Example 4

[0048] The procedures were performed in the same manner as described in Example 1, excepting that the thickness of the polyester monofilament yarn was changed to 30 D.

Example 5

[0049] The procedures were performed in the same manner as described in Example 1, excepting that the lower knit fabric used a non-conductive fiber containing a copper component in place of the conductive fiber containing a copper component.

Comparative Example 1

[0050] The procedures were performed in the same manner as described in Example 1, excepting that 25 wt. % of an 80 D cotton yarn was used for the vertical knit fabric.

Comparative Example 2

[0051] The procedures were performed in the same manner as described in Example 1, excepting that a 70 D nylon 66 yarn was used for the vertical knit fabric.

Comparative Example 3

[0052] The procedures were performed in the same manner as described in Example 1, excepting that a 70 D polyester yarn was used for the vertical knit fabric.

Comparative Example 4

[0053] The procedures were performed in the same manner as described in Example 1, excepting that the thickness of the vertical filament yarn was changed to 100 D.

Comparative Example 5

[0054] The procedures were performed in the same manner as described in Example 1, excepting that the thickness of the vertical filament yarn was changed to 10 D.

[0055] Vertical Strength Test After repeating 500 to 1,000 cycles of 20% fabric compression and recovery on ten spots in a piece of the prepared fabric with an area of 5×5 cm.sup.2, it was checked whether any dented areas were formed in the surface of the fabric.

TABLE-US-00001 TABLE 1 Surface Item 500 cycles 1,000 cycles protrusion Example 1 ◯ ◯ Good Example 2 ◯ ◯ Good Example 3 ◯ ◯ Good Example 4 ◯ ◯ Good Example 5 ◯ ◯ Good Comparative X X Good Example 1 Comparative Δ X Good Example 2 Comparative Δ X Good Example 3 Comparative ◯ ◯ Bad Example 4 Comparative ◯ Δ Good Example 5 ◯: No change in thickness throughout the repeating cycles of 20% fabric compression and recovery. Δ: One or more areas with the thickness reduced by 10% or greater throughout the repeating cycles of 20% fabric compression and recovery. X: Five or more areas with the thickness reduced by 10% or greater throughout the repeating cycles of 20% fabric compression and recovery. Surface protrusion: “Bad” if any minute protrusion was observed in the surface of the upper knit fabric after 500 repeating cycles of 20% fabric compression and recovery; and “Good” if not.

[0056] As can be seen from. Table 1, when the vertical knit fabric included a filament yarn having an appropriate thickness, that is, in Examples 1 to 5, resilience after compression was secured to reduce the gap between the upper and lower knit fabrics, thus resulting in no change in thickness.

[0057] In contrast, when the vertical knit fabric did not include a filament yarn having an appropriate thickness, that is, in Comparative Examples 1 to 3 using different fibers, Comparative Example 4 having an extremely thick monofilament yarn, and Comparative Example 5 using an extremely thin monofilament yarn, there was a defect involving a reduced gap between the upper and lower knit fabrics or a surface defect in which the vertical knit fabric formed protrusions in the upper knit fabric.

[0058] Antimicrobial Test

[0059] An antimicrobial test was conducted on the products of Example 1 using an antimicrobial fiber containing a copper component and a polyester monofilament yarn for the vertical knit fabric and Example 2 using a polyester monofilament yarn alone for the vertical knit fabric. The Korean Apparel Testing Institute (www.katri.re.kr, TEL 88-2-561-0844, FAX 88-2-569-6135) located at Dabong Tower 4F, 418 Teheran-Ro, Gangnam-Gu, Seoul was commissioned to perform the antimicrobial test.

[0060] In an antimicrobial test for Example 1 using an antimicrobial fiber in the lower and vertical knit fabrics, the prepared fabric was tested for antimicrobial activity according to the KS K 0693:2016. The antimicrobial activity was measured against Escherichia coli (ATCC25922), Staphylococcus Aureus (ATTC 6538), and Klebsiella Pneumoniae (ATTC 4352). The concentration of the inoculum solution was 0.7×10.sup.5 CFU/mL for each bacterium, and a standard cotton fabric was used as a control. As a surfactant, Tween 80 was added in an amount of 0.05% of the inoculum solution. According to the issued test report (KATAI No: KNAA18-00016180, accepted on Aug. 10, 2018 and issued on Aug. 24, 2018), the test fabric showed an antimicrobial activity of 99.9% against Escherichia coli (ATCC 25922) and over 99.9% against Staphylococcus Aureus (ATTC 6538) and Klebsiella Pneumoniae (ATTC 4352).

[0061] In an antimicrobial test for Example 2 using an antimicrobial fiber only in the lower knit fabric, the prepared fabric was tested for antimicrobial activity according to the KS K 0693:2016. The antimicrobial activity was measured against Escherichia coli (ATCC 25922), Staphylococcus Aureus (ATTC 6538), and Klebsiella Pneumoniae (ATTC 4352). The concentration of the inoculum solution was 1.2×10.sup.3 CFU/mL for Escherichia coli (ATCC 25922), 1.0×10.sup.3 CFU/mL for Staphylococcus Aureus (ATTC 6538), and 0.7×10.sup.3 CFU/mL for Klebsiella Pneumoniae (ATTC 4352), and a standard cotton fabric was used as a control. As a surfactant, Tween 80 was added in an amount of 0.05% of the inoculum solution. According to the issued test report (KATAI No: KNAA18-00015377, accepted on Jul. 30, 2018 and issued on Aug. 3, 2018), the test fabric showed an antimicrobial activity of 74.0%, 81.3% and 82.7% against Escherichia coli (ATCC 25922), Staphylococcus Aureus (ATTC 6538) and Klebsiella Pneumoniae (ATTC 4352), respectively. The fabric product using an antimicrobial fiber only in the lower knit fabric had an antimicrobial activity of about 74 to 82%, which was lower than the over 99% antimicrobial activity of Example 1.