FABRIC AND METHOD OF MAKING THE SAME

Abstract

A multi-ply fabric is disclosed. The fabric has a top yarn arranged to face an atmosphere and a bottom yarn connected to the top yarn, arranged to contact a surface of a user's body. The bottom yarn has a surface area to volume ratio (SA:V) that is greater than the SA:V of the top yarn. In some embodiments, the bottom yarn has a SA:V that is about 25% to about 50% greater than the SA:V of the top yarn.

Claims

1. A fabric comprising: a top yarn arranged to face an atmosphere; a bottom yarn connected to the top yarn by knitting and/or weaving, the bottom yarn being arranged to contact a surface of a user's body, wherein the bottom yarn has a surface area to volume ratio (SA:V) that is about 25% to about 50% greater than the SA:V of the top yarn.

2. The fabric as defined in claim 1, wherein the bottom yarn comprises a plurality of bottom fibers and the top yarn comprises a plurality of top fibers, and wherein an average diameter of the plurality of bottom fibers is less than an average diameter of the top fibers.

3. The fabric as defined in claim 2, wherein each of the plurality of bottom fibers is separated by a bottom fiber gap, and each of the plurality of top fibers is separated by a top fiber gap, and wherein an average width of the bottom fiber gap is less than an average width of the top fiber gap.

4. The fabric as defined in claim 2, wherein the number of bottom fibers in the bottom yarn is greater than the number of top fibers in the top yarn.

5. The fabric as defined in claim 1, wherein the cross-sectional shape of the bottom yarn is non-spherical.

6. The fabric as defined in claim 1, wherein the bottom yarn comprises a hollow body.

7. The fabric as defined in claim 1, wherein the hydrophilicity of the bottom yarn is greater than the hydrophilicity of the top yarn.

8. The fabric as defined in claim 1, wherein the difference in denier of the top fibers and the bottom fibers is less than about 15%.

9. A fabric comprising: a top yarn arranged to face an atmosphere; a bottom yarn connected to the top yarn by knitting and/or weaving, the bottom yarn being arranged to contact a surface of a user's body, wherein the bottom yarn comprises a plurality of bottom fibers and the top yarn comprises a plurality of top fibers, and wherein an average diameter of the plurality of bottom fibers is less than an average diameter of the top fibers.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The preferred embodiment of the invention will be described by reference to the drawings thereof in which:

[0027] FIG. 1 is a close-up cross-sectional view of a prior art Y+O yarn;

[0028] FIG. 2 is a close-up cross-sectional view of a prior art wicking yarn with increased surface area for enhanced wicking;

[0029] FIG. 3 illustrates the movement of body heat and moisture moving from the human body to the environment through the fabric of the present invention

[0030] FIG. 4 illustrates the movement of body heat and moisture moving from the human body to the environment through the fabric of the present invention

[0031] FIG. 5. illustrates the movement of moisture and heat transferring from the human body to the environment of the present invention.

[0032] FIG. 6 is perspective view of a a cross fiber of FIG. 2;

[0033] FIG. 7 is a close up view of the fabric of the present invention showing a general form of the fabric stitching pattern including plurality of wrap yarns and single weft yarns;

[0034] FIG. 8 is a demonstration of the pattern construction form and arrangement of the yarns in perspective to a knitting machine;

[0035] FIG. 9 is a close up view of the fabric of the present invention showing a general form of the front of a single jersey knit face stitching pattern;

[0036] FIG. 10 is a close up view of the fabric of the present invention showing a general form of the back of a single jersey knit face stitching pattern;

[0037] FIG. 11 is a close up view of the fabric of the present invention showing a general form of the stitching of a type of yarn that will be combined in order to generate a final fabric;

[0038] FIG. 12 is a close up view of the fabric of the present invention showing a general form of the stitching of another type of yarn that will be combined in order to generate a final fabric;

[0039] FIG. 13. is a close up view of the fabric of the present invention showing a general form of the combination of the two types of yarns combined in order to accelerate the hydraulic abilities knit face stitching pattern;

[0040] FIG. 14 is a close up view of the fabric of the present invention showing the positioning of the bobbins and sinker on a knit machine in order to conduct the fabrication of the fabric;

[0041] FIG. 15 is a sample of the vertical wicking benefits of a yarn utilized in the present invention in comparison to other types of yarns;

[0042] FIG. 16 is a sample of the diffusion area that a yarn utilized in the present invention in comparison to other types of yarns; and

[0043] FIG. 17 is a sample of the specification of the fabric utilized in the present invention in comparison to other types of yarns.

[0044] FIG. 18 is a schematic diagram showing a fabric according to an example embodiment.

DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE INVENTION

[0045] Objects with higher surface area to volume ratios (SA:V) move liquid molecules at a faster rate than objects with lower SA:V. This explains why fine salt crystals dissolve quicker in water than coarse salt crystals for any given mass. This occurs because objects with higher SA:V allow molecules to diffuse more quickly and easily than objects with lower SA:V. For this very reason, our lungs have a cluster of porous arteries and fish gills have numerous spikes in order to move molecules of air.

[0046] An increase in SA:V results in a corresponding increase in exposure to the environment. More contact with an environment increases the rate of absorption or loss of water. Objects with higher SA:V are also effective at regulating temperatures in unfavorable environments; for example, cacti have numerous pines and lizards spread their gills in order to dissipate heat. The higher the SA:V an object possesses the faster a particle (including air or water) responds to change in environmental condition such as temperature or moisture.

[0047] When we apply this phenomena to textile yarn, a yarn with an intricate cross section has a higher SA:V than an ordinary spherical round yarn. An intricately cross sectioned yarn, therefore, moves moisture much faster than a spherical yarn or hollow yarn. A cross sectioned or Y section yarn diffuses water from a person's skin into the air at a very high rate. Textiles made from these yarns are typically referred to as wicking yarn as shown in FIGS. 1 and 2.

[0048] FIGS. 3 to 5 generally illustrate the workings of the present fabric. Advantageously, the present invention employs a combination of two yarns in constructing a singular fabric. The fabric is created by either knitting or weaving two yarns with differing SA:V. Doing so, regulates the rate of water flow within the fabric and controls the rate of evaporation of a person's perspiration. By creating a fabric with two yarns of differing SA:V, the fabric cools a person's skin more rapidly than traditional wicking fabric.

[0049] The two yarn system of the present invention combines a yarn with higher SA:V with a yarn with a lower SA:V. The fabric is constructed so that the yarn with the higher SA:V is situated next to a person's skin (bottom yarn) and the yarn with the lower SA:V (top yarn) is placed over the fabric with the higher SA:V, and is exposed to the external environment as best illustrated in FIG. 7. The bottom yarn is placed next to a person's skin so that water molecules (sweat) are absorbed at a fast rate and conducted away from the skin through yarn bobbin linkages between the bottom and top yarns. Water molecules stored at the surface of the top yarn will evaporate due to flow of air from the environment or body heat. The evaporation of liquid into the air absorbs heat energy from the body to help cooling down a persons' body temperature.

[0050] Currently, there are many fabrics made from a single yarn with high SA:V ratios such as: Coolmax™, Coolpass™, Coolbest™, Cooltouch™, and Cooldry™. These fabrics are produced from Y cross sections and other various cross sections as shown in FIGS. 1, 2 and 6. Such fabrics also tend to maximize their SA:V of their yarns in order to maximize their wicking properties and are hydrophilic in nature.

[0051] Unlike these traditional wicking fabrics, which use a single wicking yarn, the present invention uses a two yarn multi SA:V system. The combination of two yarns with differing SA:V is applicable to not only synthetic fibers, but to various combinations of yarns for example, combinations of synthetic fiber with natural fibers.

[0052] To increase the SA:V of a particular yarn, one can also break the yarn structure by brushing, sanding or peaching. When a yarn is brushed or peached, the SA:V is increased to help trap more liquid and to increase the variance of SA:V among the two layers of yarn.

[0053] Yarns embedded with a polymer with additional features such as: anti-odor, anti-microbial, and infra-red absorption, does not affect the cooling feature of the present invention so long the bottom yarn (the yarn next to a person's skin) has a higher SA:V than the top yarn (the yarn exposed to the external environment).

[0054] The present invention is a multi-ply fabric. The present fabric: cools when exposed to a liquid, such as perspiration from an individual's body, for example; is able to wick (transport) perspiration, water or other liquid from an object such as an individual's skin; is able to absorb a liquid at a weight that is a plurality of the weight of the fabric; efficiently regulates the evaporation rate and retains a liquid with minimal loss of the liquid over an extended period of time; controls moisture release, that is, it provides moisture management; and is reusable, while retaining all of these characteristics from use-to-use. The present invention also is a method of making the fabric having these characteristics.

[0055] The side of the fabric to be positioned adjacent to the object to be cooled, referred to herein as the back side, is configured to enhance the transfer of liquid away from the object, such as by wicking, while the other side of the fabric that is spaced away from the object is configured to slow evaporation. The back side may be relatively more porous than the front side as a mechanism to facilitate liquid transfer. Further, its wicking characteristics may be optimized, such as by using fibers made of hydrophobic material and/or with large peripheral surface area. On the other hand, the front side may be relatively less porous than the back side as a mechanism to slow liquid evaporation (by trapping the liquid, or at least slowing its progression to the outer surface of the fabric). Further, its wicking characteristics may be minimized, such as by using fibers made of absorptive or at least relatively hydrophilic material and/or with reduced peripheral surface area.

[0056] The selected materials and material configurations for the back side and the front side, when peached as described herein, act in concert to enhance the movement/transportation of liquid from the surface of the object to the core of the fabric's construction. Cooled liquid either moves back toward the object or dwells long enough within the fabric to establish a sufficient heat gradient to effectively draw heat away from the object surface. This results in moisture movement in a controlled manner that enhances and extends the ability of the fabric to transfer heat between the object and the interior of the fabric. In effect, warm liquid adjacent to the surface of the object is drawn away from the object surface at the back side of the fabric and moved to the front side, while cooled liquid within the fabric is sufficiently close to the object at the back side to effect cooling. The regulated slower evaporation of the liquid from the fabric at the top side provides the extension of time for the cooled liquid within the fabric to act as a heat sink for the object.

[0057] While some manner of making a fabric creates interstices that act as fluid pathways, the combination of the material selection and peaching of the fabric as described herein makes that pathway characteristic much more substantial, creating a capillary web system that stores and orients the moisture molecules and holds them in suspension until such time as the fabric is activated; thus setting the molecules in motion and causing a disorientation of the moisture molecules so that they are inclined to move toward or away from an object to be cooled or maintained at a temperature. This recycling of moisture to and from the fabric core creates a regulated, controlled, extended evaporative cooling device.

[0058] Referring to FIG. 18, an aspect of the invention relates to a fabric 10 comprising a top side 12 and a back side 14. The top side 12 comprises a top yarn 16. The bottom side 14 comprises a bottom yarn 18. The top side 12 is arranged to face the atmosphere. The bottom side 14 is arranged to contact a surface of an object (i.e., a user's body). The top yarn 16 comprises a plurality of top fibers 20. The bottom yarn 18 comprises a plurality of bottom fibers (not shown). To facilitate movement of moisture from the surface of the object, yarns having different SA:V are used as bottom yarn 18 and top yarn 16. In some embodiments, the SA:V of the bottom yarn 18 is greater than the SA:V of the top yarn 16. In some embodiments, the SA:V of the bottom yarn 18 is about 25% to about 50% greater than the SA:V of the top yarn 16, and in some embodiments, between 30% to 40% greater.

[0059] The variance of the SA:V between the top and bottom yarns 16, 18 may be adjusted to control the rate of at which moisture from the surface of the object moves through the fabric 10 and evaporates into the atmosphere. Adjusting the variance of the SA:V between the top and bottom yarns 16, 18 may create a difference between a rate of transfer of moisture out of the top side 12 of the fabric 10 and a rate of transfer of liquid from a surface of the object to the back side 14 of the fabric 10. In some embodiments, the rate of transfer of liquid out of the top side 12 of the fabric 10 is slower than the rate of transfer of liquid from the surface of the object to the back side 14 of the fabric 10.

[0060] In some embodiments, the hydrophilicity of the bottom yarn 18 is greater than the hydrophilicity of the top yarn 16. In some embodiments, the rate at which bottom yarn 18 absorbs moisture is greater than the rate at which top yarn 16 absorbs moisture.

[0061] In some embodiments, the top and/or bottom fibers each comprises a non-spherical cross-sectional shape. For example, the top and/or bottom fibers may comprise a Y-, T- X-, star-cross-sectional shape. The top and bottom yarns 16, 18 may each comprise a plurality of fibers having the same cross-sectional shape, or a combination of one or more different cross-sectional shapes. In some embodiments, the top and/or bottom fibers comprises a hollow fiber body.

[0062] In some embodiments, the average diameter of the bottom fibers that form the bottom yarn 18 is less than the average diameter of the top fibers 20 that form the top yarn 16.

[0063] In some embodiments, the number of bottom fibers that form the bottom yarn 18 is greater than the number of top fibers 20 that form the top yarn 16.

[0064] Each of the bottom fibers may be separated from an adjacent one of the bottom fibers by a bottom fiber gap (not shown). Each of the top fibers 20 may be separated from an adjacent one of the top fibers 20 by a top fiber gap 26. In some embodiments, the average width of the bottom fiber gaps (i.e., average distance between two bottom fibers) is less than the average width of the top fiber gaps 26 (i.e., average distance between two top fibers 20).

[0065] The top yarn 16 and bottom yarn 18 may comprise the same material or different materials.

[0066] In some embodiments, the difference in denier (or thickness) between the top fibers 20 and the bottom fibers is less than about 15%. In some embodiments, the denier of the top fibers 21 is the same or substantially the same as the denier of the bottom fibers.

[0067] In some embodiments, the top fibers 20 and/or bottom fibers are physically or structurally modified to achieve a desired SA:V. In some embodiments, the physical or structural modification comprises one or more of twisting the fibers, and/or spinning the fibers, and/or brushing or combing the fibers, and/or drawing the fibers, and/or creating texture on the surface of the fibers. In some embodiments, only the bottom fibers (and not the top fibers 20) are physically or structurally modified.

[0068] In some embodiments, the top fibers 20 and/or bottom fibers are not chemically treated. In some embodiments, the top yarn 16 and/or bottom yarn 18 is free from any chemical solvents.

[0069] Aspects of the invention relate to methods of making the fabric 10. The method comprises combining the top yarn 16 and the bottom yarn 18 to form the fabric 10. The combining of the top and bottom yarns 16, 18 may comprise knitting the yarns using a double knit machine. The combining of the top and bottom yarns 16, 18 may comprise a weaving method. In some embodiments, the top yarn 16 is not interlooped with the bottom yarn 18 to form the fabric 10. In such embodiments, the top yarn 16 is arranged at top side 12, and the bottom yarn 18 is arranged at bottom side 14. In some embodiments, the top yarn 16 is linked to the bottom yarn 18 by looping through bobbins in the bottom yarn 18, and the bottom yarn 18 is linked to the top yarn 16 by looping through bobbins in the top yarn 16. In some embodiments, the top and bottom yarns 16, 18 are not connected by lamination and/or otherwise use of any chemicals.

[0070] The present invention has been described with respect to various examples. Nevertheless, it is to be understood that various modifications may be made without departing from the spirit and scope of the invention as described by the following claims. While embodiments of the invention have been described and illustrated, such embodiments should be considered illustrative of the invention only. The invention may include variants not described or illustrated herein in detail. Thus, the embodiments described and illustrated herein should not be considered to limit the invention as construed in accordance with the accompanying claims.