MULTI-LAYER APPAREL AND ACCESSORY CONSTRUCTION FOR COOLING AND VENTILATION

Abstract

A cooling garment, and a method of construction thereof, includes: a first layer configured to be adjacent to a wearer's skin and comprising exemplary cooling fabrics capable of providing a conductive cooling effect when preferably when wet-activated; a second layer adjacent to the first layer and comprising a spacer material that allows for convective air flow; and a third layer adjacent to the second layer and comprising perforated holes in order to enhance the airflow to the first and second layers.

Claims

1. A garment or accessory, comprising: a first layer, wherein the first layer includes a plurality of synthetic filament yarn with a modified cross-section; a second layer, wherein the second layer includes another plurality of synthetic filament yarn in a mesh construction; and a third layer, wherein the third layer includes a first plurality of perforated holes, wherein the first plurality of perforated holes is formed by laser cutting, and wherein the first plurality of perforated holes pores having a diameter of 0.5 mm to 15 mm.

2. The garment to claim 1, wherein the first plurality of perforated holes is arranged in a first predetermined pattern.

3. The garment according to claim 2, wherein the first predetermined pattern is a logo or text.

4. The garment according to claim 2, wherein the first layer comprises a second plurality of perforated holes.

5. The garment according to claim 4, wherein the second plurality of perforated holes are arranged in a second predetermined pattern different than the first predetermined pattern.

6. The garment according to claim 4, wherein the first predetermined pattern is aligned with the second predetermined pattern.

7. The garment according to claim 4, wherein the second layer comprises a third plurality of perforated holes.

8. The garment according to claim 7, wherein at least some of the third plurality of perforated holes do not align with the first plurality of perforated holes.

9. A garment comprising: a garment body; and a collar coupled to the garment body, wherein the collar comprises: a first section adjacent to a skin of the wearer, and; a second section configured to be folded down over the first section, wherein the first section comprises a first vent panel comprising: a first layer, wherein the first layer includes a plurality of synthetic filament yarn with a modified cross-section; a second layer, wherein the second layer includes another plurality of synthetic filament yarn in a mesh construction; and a third layer, wherein the third layer includes a first plurality of perforated holes, wherein the first plurality of perforated holes is formed by laser cutting, and wherein the first plurality of perforated holes pores having a diameter of 0.5 mm to 15 mm.

10. The garment according to claim 9, wherein the second section comprises: a second vent panel configured to at least partially overlap the first vent panel when the collar is folded down.

11. The garment according to claim 10, wherein the second vent panel comprises: a second plurality of perforated holes.

12. The garment according to claim 11, wherein the second plurality of perforated holes partially overlap with the first plurality of perforated holes.

13. The garment according to claim 11, wherein the second plurality of perforated holes extend through all layers of the second vent panel.

14. The garment according to claim 11, wherein the second plurality of perforated holes circumscribe an entirety of the second section.

15. The garment according to claim 9, wherein the garment body comprises: at least one body panel having a same construction as the first section.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] FIG. 1A illustrates an exemplary garment.

[0027] FIG. 1B illustrates layers of an exemplary garment.

[0028] FIGS. 2A-2E illustrate exemplary warp knit constructions.

[0029] FIG. 3 illustrates a second layer of an exemplary garment.

[0030] FIGS. 4A-4C illustrate cross-sectional views of synthetic filament yarns.

[0031] FIGS. 5A-5D illustrate exemplary covered synthetic filament yarns.

[0032] FIG. 6 illustrates an exemplary head-covering garment.

[0033] FIGS. 7A-13B illustrate exemplary embodiments of exemplary garments.

DETAILED DESCRIPTION OF EMBODIMENTS

[0034] The following description of embodiments provides non-limiting representative examples referencing numerals to particularly describe features and teachings of different aspects hereof. The embodiments described should be recognized as capable of implementation separately, or in combination, with other embodiments from the description of the embodiments. A person of ordinary skill in the art reviewing the description of embodiments should be able to learn and understand the different described aspects of this disclosure. The description of embodiments should facilitate understanding of these embodiments to such an extent that other implementations, not specifically covered but within the knowledge of a person of skill in the art having read this description, would be understood to be consistent with an application of these embodiments.

[0035] FIG. 1A illustrates an exemplary garment. As depicted in the FIG. 1A, exemplary garment 100 can be a headband. However, in other embodiments, the exemplary garment can be a shirt, a pair of shorts, a towel, a hat, etc. According to an embodiment, the exemplary garment 100 can include a first layer 104, a second layer 106, and a third layer 108, which are depicted in more detail in FIG. 1B.

[0036] According to an embodiment, the first layer 104 can be adjacent to the skin 102 of a particular user. Further, the first layer 104 can include synthetic yarn. For example, the first layer 104 can include modified cross-section synthetic filament yarn to aid in the moisture transport and evaporation. The modified cross-section can be a cross-section other than round which can include but not limited to: trilobal, rectangular, dog-bone, or in cloud shapes. In general, modified cross-sections in yarn can increase the spread of moisture which increases the surface area spread and the evaporative effect of the yarn over non-modified (rounded) cross-section yarn. These yarns can also contain embedded cooling particles (e.g., titanium dioxide, jade, mica, and/or graphene) to increase the Q-max rating (instant cool touch) of the first layer 104. In this regard, the Q-max can be greater than 0.130 W/cm.sup.2. Further, the cumulative cooling power of the first layer 104 can exceed a heat flux of 5,000 W/m.sup.2 (watts per square meter) based on a modified version of the ASTM F1868 entitled Standard Test Method for Thermal and Evaporative Resistance of Clothing Materials Using a Sweating Hot Plate. Further, the weight range of the first layer 104 can be between 20 gsm (grams per square meter) to 500 gsm.

[0037] According to an embodiment, the first layer 104 can include a single knit jersey construction weighing approximately 190 gsm with a fiber content of approximately 92% polyester and 8% spandex. According to another embodiment, the fiber content can range from 70%-100% polyester or nylon and 0%-30% spandex. In this regard, the corresponding yarns can be evaporative polyester and can include (i) a modified cross-section for increased capillary action and evaporative ability and (ii) embedded particles/minerals for adding a cool touch (e.g., Q-max) effect. Further, the first layer 104 can include a yarn filament count of greater than 24 filaments per end of polyester or nylon yarn used.

[0038] Further, according to another embodiment, the first layer 104 can be constructed using a warp knitting method. Warp knits include, but are not limited to, tricot, raschel, spacer, and lace. A first example for warp knit tricot 4-bar construction, depicted in FIGS. 2A-2E, utilizes the following stitch and yarn combinations: FIG. 2ABar 11-0/2-3 (evaporative yarn such as aqua-X); FIG. 2BBar 21-2/1-0 (absorbent yarn such as mipan XF); FIG. 2CBar 30-1/2-1 (evaporative yarn such as askin); and FIG. 2DBar 41-0/1-2 (elastic yarn such as spandex). According to an embodiment, bar 1 is a 35 Denier/24 filament nylon fully drawn yarn or draw textured yarn; bar 2 is a 50 Denier/48 filament conjugated polyester/nylon bi-component fully drawn yarn; bar 3 is a 75 Denier/36 filament polyester draw textured yarn; and bar 4 is a 40 Denier spandex.

[0039] This configuration results in a fabric having a density of 100-600 gsm, e.g., 160-400 gsm. The combined first layer 104 resulting from this stitch is depicted in FIG. 2E. Further, The yarn Deniers and filament counts used on bars 1-4 can be varied using the following ranges: bar 1: evaporative yarn with Denier range10 Denier-200 Denier, filament range1 filament-400 filaments; bar 2: absorbent yarn with denier range10 Denier-200 Denier, filament range1 filament-400 filaments; bar 3: evaporative yarn with Denier range10 Denier-200 Denier, filament range1 filament-400 filaments; and bar 4: elastomeric yarn with Denier range10 Denier-340 Denier. As another example, bar 2 may utilize a yarn such as Nanofront polyester yarn manufactured by Teijin which has significantly smaller filaments than traditional absorbent yarns. Another embodiment of the first layer 104 can use the following 4-bar knitting stitch and yarn combination: bar 11-0/2-3 (evaporative yarn such as askin); bar 21-2/1-0 (absorbent yarn such as Hyosung mipan XF); bar 30-1/2-1 (evaporative yarn such as askin); and bar 41-0/1-2 (clastic yarn such as spandex). In this stitch configuration, bar 1 is a 45 Denier/24 filament polyester fully drawn yarn; bar 2 is a 50 Denier/48 filament polyester and nylon conjugated fully drawn yarn; bar 3 is a 75 Denier/36 filament polyester draw textured yarn; and bar 4 is a 40 Denier spandex. In both knitting stitch examples, bars 1 and 3 are cool touch/quick dry/absorption materials as have already been described. The Q-max for these yarns is greater than 0.140 W/cm.sup.2 on the face side and 0.120 W/cm.sup.2 on the back side of the material which indicates a cooling touch effect as has already been described. The wet Q-max for these yarns is greater than 0.280 W/cm.sup.2 on face side and 0.180 W/cm.sup.2 on back side. Bar 2 is a conjugated highly absorbent yarn (mipan XF) which has a wicking rate and a wicking distance more than twice that of cotton of equivalent density. The spandex yarn provides hydrophobic properties, provides stretch properties, and a draping effect. Further, according to an embodiment, the warp knit patterns described with respect to FIGS. 2A-2E can be modified. For example, in FIG. 2A, bar 1-0/2-3 can be modified to 1/0-3/4.

[0040] Further, the first layer 104 can also be constructed using a warp knit spacer. A warp knit spacer machine can insert additional yarns such as a mono-filament yarn to provided added thickness to the first layer 104. This added thickness created by yarns such as mono-filament yarns can be substituted or combined intermittently with conjugate yarn while the outside yarns used can be highly evaporative yarns or other yarns. Further, the first layer 104 can also be constructed using a warp knit jacquard. 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 cooling fabric with or without patterns such as mesh and graphics.

[0041] Further, the first layer 104 can be constructed using a spacer implementing a circular knitting method. For example, the first layer 104 can be constructed using a circular knit spacer machine. A circular knit spacer machine can insert additional yarns such as a mono-filament yarn to provided added thickness to the material of the first layer 104. This added thickness created by yarns such as monofilament yarn can be substituted or combined intermittently with conjugate yarn while the outside yarns can be highly evaporative yarns or any other yarns. Further, the first layer 104 can also be achieved using a circular knit interlock, ponte, or pique constructions. A circular knit interlock machine can insert additional evaporative and absorbent yarns to provide added evaporative cooling ability to the fabric. The first layer 104 can also be achieved using a circular knit jacquard. A circular knit jacquard can be utilized to create unique patterns, such as, but not limited to, fancy knits, mesh, body-mapped patterns, and other three-dimensional designs. Circular knit jacquard can creatively place highly evaporative yarns with highly absorbent yarns within the same construction to create a uniquely designed cooling fabric with or without patterns such as mesh and graphics.

[0042] According to an example embodiment, the second layer 106 can include a spacer fabric construction, as depicted in FIG. 3. In this example, the second layer 106 can include a top surface layer 301, a bottom surface layer 302 and spacer fabric 303. The spacer fabric 303 in the second layer 106 can include a breathability (as tested by ASTM E96) of greater than 800 MVTR (e.g., moisture vapor transfer rate) within twenty-four hours. The spacer fabric can be knitted using a mesh construction at least on one side (e.g., top surface layer 301 or bottom surface layer 302) of the second layer 106 in order to allow for air pockets and greater air flow. Further, the weight range for the spacer fabric can be between 100 gsm and 500 gsm. Further, the pile height of the spacer fabric can be at least one millimeter (mm). Further, the spacer fabric can also be infused with cooling yarns which allow for greater evaporation and cool touch over other materials. The yarns used can be an inner evaporative nylon yarn such as aqua-X, a middle absorbent bi-component nylon/polyester yarn such as mipan XF) and an outer evaporative polyester yarn such as askin. Exemplary yarns which can be used as spacer fabric are depicted in FIGS. 4A and 4B. Further, according to an embodiment, the spacer fabric can be constructed using one of the circular knitting method or warp knitting method described above.

[0043] According to an example embodiment, layers 104 and 106 can comprise of a Dual Function Absorbing and Cooling Textile as described, for example, in PCT/US19/15239, which is expressly incorporated herein in its entirety by reference thereto. For example, the dual function ability of this textile can replace both layers 104 and 106. This Dual Function Absorbing and Cooling textile is a warp knit spacer textile that provides a dual function two-sided textile capable of absorbing up to four times its weight in perspiration on a loop absorbent side. Also, while wetted to activate, the same textile can provide increased conductive cooling on a non-loop (flat) absorbent side. More particularly, the multi-layer warp knit spacer fabric construction provides the ability to absorb sweat efficiently away from the skin while the same textile can be used to cool the skin to below a current temperature of the skin for a longer duration, primarily when wetted, but secondarily in dry state. Described in PCT/US19/15239 is an integrally formed warp knitted spacer structure that includes four bars of yarn which collectively work together to produce the textile.

[0044] According to an embodiment, the third layer 108 can correspond to the outer shell of the garment 100 and can include a plurality of vent pores (perforated holes) which can provide convective cooling through ventilation and evaporation. The material used in the third layer can be a rip stop material weighing less than 150 grams per square meter (gsm) and includes, for example, synthetic fiber such as polyester or nylon so that this layer can be laser perforated which allows for greater breathability. The weight range of this third layer material can be anywhere from 10 gsm to 400 gsm. It can also be constructed using any woven pattern or knit pattern material within the weight range of 10 gsm to 400 gsm. This material allows for ventilation to the inner hat band layer either by high breathability, through perforations, or other mechanisms.

[0045] In some embodiments, the third layer 108 comprise a plurality of vent pores or perforations to assist with evaporation and wicking. The pores may have different or the same sizes ranging from 0.5 mm to 15 mm each. The vent pores may be arranged in a repeating pattern, a particular design (e.g., a logo), or non-repeating arrangement. The vent pores may be formed by laser perforations or other known techniques. The vent pores may have a number of different shapes and sizes including, but not limited to circles, squares, triangles or stars. The vent pores may be different or the same sizes ranging from 0.5 mm to 15 mm each. In some embodiments, the first layer 104 and second layer 106 may also comprise vent pores in a similar or different arrangement as that of the third layer 108.

[0046] FIGS. 4A-4B illustrate cross-sectional views of synthetic filament yarns according to exemplary embodiments. For example, FIG. 4A depicts a synthetic filament yarn (e.g., polyester and/or nylon) having a unique cross section. According to an embodiment, the unique cross section creates channels in the yarn for moisture to move and evaporate more quickly. Furthermore, this unique yarn allows for better evaporation and therefore provides greater evaporative cooling for the described embodiments. Further, FIG. 4B depicts a synthetic filament yarn having a star-shaped cross section. In this regard, the star-shaped cross section provides a higher absorbency, and therefore, holds water more efficiently. This unique yarn can provide greater liquid absorption for the materials used herein, which can be used in combination with evaporative yarns to provide a longer evaporative cooling effect. According to an embodiment, a differentiated cross section helps moisture move and spread to the outer layer of the fabric. Further, the synthetic filament yarn can also include absorbent microdenier yarn. According to an embodiment, the absorbent microdenier yarn can be less than 1 denier per filament (dpf). Further, the absorbent microfiber yarn can use multiple filaments (e.g., 72 filaments) to provide absorbent properties. Further, according to another embodiment, conjugated bi-component special cross-section yarn can be used to provide extreme absorbent properties. Further, by splitting the yarn, more surface area, and therefore, more pockets can be created for absorbency. Further, FIG. 4C depicts the cross-sections of cooling nylon, cooling polyester, and regular polyester.

[0047] FIGS. 5A-5D illustrates exemplary covered synthetic filament yarn. For example, FIG. 5A illustrates a double-covered synthetic filament yarn. In particular, FIG. 5A depicts a covered synthetic filament yarn 500 including a core predominately synthetic spun or filament yarn 502 being covered by another synthetic filament yarn 504 in a double-covered manner. FIG. 5B illustrates a single-covered synthetic filament yarn. In this regard, FIG. 5B depicts the core predominately synthetic spun or filament yarn 502 being covered by another synthetic filament yarn 504 in a single-covered manner. Further, FIG. 5C illustrates an air jet-covered synthetic filament yarn. In this regard, FIG. 5B depicts the core predominately synthetic spun or filament yarn 502 being covered by another synthetic filament yarn 504 via air jet covering technique. Lastly, FIG. 5D illustrates a core-spun synthetic filament yarn. In this regard, the core predominately synthetic spun or filament yarn 502 is wrapped with other synthetic filament yarn 504 and spun into a single yarn 500. The list in Table 1 below describes possible combinations of a core synthetic filament yarn 502 and another synthetic filament yarn 504.

TABLE-US-00001 TABLE 1 Total Estimated Core Yarn Covered Yarn Denier 30 Ne Synthetic Filament Evaporative 327 Denier Total 80% Polyester/20% Cooling Polyester 150 (Single covered) Tencel Spun Yarn Denier/72 Filaments Draw Blend Textured Yarn (DTY) 30 Ne Synthetic Filament Evaporative 317 Denier total 80% Polyester/20% Cooling Polyester 2 ply/70 (Single covered Tencel Spun Yarn Denier/26 Filament Fully yarn) Blend Drawn Yarn (FDY) 30 Ne Synthetic Filament Evaporative 317 Denier total 80% Polyester/20% Cooling Nylon 140 Denier/136 (Single covered Tencel Spun Yarn Filament Draw Textured Yarn yarn) Blend (DTY) 30 Ne Synthetic Filament Evaporative 317 Denier total 80% Polyester/20% Cooling Nylon 2 ply/70 (Single covered Tencel Spun Yarn Denier/48 Filament Fully yarn) Blend Drawn Yarn (FDY)

[0048] FIG. 6 illustrates an exemplary garment. In particular, FIG. 6 depicts the exemplary garment 100 as a hat 500. In this example embodiment, the hat 600 can include the garment 100 including the first, second and third layers 104, 106 and 108. The first layer 104 and the third layer 108 are displayed in the FIG. 6.

[0049] According to an embodiment, the exemplary garment 100 can provide the following advantages: cooling power that is 40% greater than normal garment constructions as measured by the modified ASTM Method F1868; instant cool touch as defined as Q-max?0.130 when dry and ?0.180 when wet; increased air ventilation and breathability, which helps enhance conductive and convective cooling; and, when wet-activated, (i) the wicking and absorbent ability allows for a temperature decrease of thirty degrees below body temperature and (ii) the duration of the cooling can extend to approximately two hours depending on external humidity/temperature conditions.

[0050] The garment as described herein may form a portion of a sun protection device, such as that described in U.S. Pat. No. 9,402,432, which is expressly incorporated herein in its entirety by reference thereto. In particular, a drape (or other portion) of such a sun protection device may be formed of the garment described herein. Moreover, the drape (or other portion) of such a sun protection device may be formed of the textile described in PCT/US19/15239, the textile and/or fabric described in U.S. patent application Ser. No. 16/077,353, the fabric described in U.S. patent application Ser. No. 16/100,939, the fabric described in U.S. patent application Ser. No. 16/749,016, and/or the fabric described in PCT/US2020/014529, each of which is expressly incorporated herein in its entirety by reference thereto.

[0051] FIGS. 7A and 7B illustrate exemplary garment 100 having a panel 702 that would rest against the rear of the neck formed from a fabric having first layer 104, second layer 106, and third layer 108. In this embodiment, the first layer 104 of panel 702 is in contact with the rear of the neck of the wearer (below the collar). The third layer 108 is exposed to the environment on the exterior of the shirt. In the depicted embodiment, the panel 702 has a half moon shaped. The third layer 108 may comprise vent pores on third layer 108. In some embodiments, vent pores may also be added to first layer 104 and second layer 106.

[0052] FIGS. 8A and 8B illustrate an exemplary garment 100 having yoke panel 802 and side panels 804. In this embodiment, the yoke is formed from yoke panel 802 in which the first layer 104 is against the skin of the wearer and the third layer 108 is exposed to the environment. Additionally, garment 100 may comprise one or more side panels 804. The side panels 804 may be placed along the sides of garments 100 or may extend from the side of the garment to the bottom of the sleeves to form under arm gussets. It should be obvious to one of ordinary skill in the art that vent panels can be added to any portion of the garment 100 as needed.

[0053] The size of the vent pores in yoke panel 802 and/or side panels 804 can be the same or different. For example, the vent pores in yoke panel 802 may be larger or more numerous that hose in side panels 804. In some embodiments, the vent pores may also be made in first layer 104 of yoke panel 802 or under arm panels 804 or through all three layers 104, 106, and 108.

[0054] FIG. 9 depicts an exemplary garment 100 having one or more cooling channels 902 or cooling panels 904. The cooling channels 901 are preferably formed by a mesh fabric (e.g., a one-layer fabric) having a plurality of vent pores. The cooling panels 904 preferably have a first layer 104 that contacts the skin of the wearer and a third layer 108 that is exposed to the environment. Vent pores may be formed through the third layer 108 as has already been described or through all three layers 104, 106, and 108. The cooling channels 902 and cooling panels 904 can be placed anywhere on the garment 100 as needed. In the depicted example, the cooling channels 902 and cooling panels 904 are placed horizontally across the front of the garment 100.

[0055] In some embodiments, a collar panel 1002 may be added to the collar 1004 of an exemplary garment 100 as depicted in FIGS. 10A and 10B. Here, the first layer 104 of the collar panel 1002 forms the lower part of collar 1004. The vent pores in third layer 108 are not visible when the outer layer of collar 1004 is folded down. The first layer 104 of collar panel 1002 rests against the skin of the wearer and helps to aid in cooling the wearer.

[0056] To help with cooling of collar panel 1002, vent pores 1104 may be added to the part of collar 1004 that folds down over third layer 108 of collar panel 1002. As depicted in FIGS. 11A and 11B, a plurality of vent pores 1104 may be added through the entirety of the collar 1004 or just through an exterior layer. In a preferred embodiment, the vent pores 1104 at least partially or wholly overlap with collar panel 1002 to maximize cooling. Since vent pores 1104 are visible while garment 100 is being worn, they may be arranged in a design or pattern that is aesthetically pleasing to a wearer or viewer of the garment.

[0057] FIG. 12 depicts an exemplary garment 100 in which additional vent pores 1202 have been added to an interior of collar 1004 or collar panel 1002. The additional vent pores 1202 may extend around an entirety of the interior of collar 1004 or just along a portion of collar 1004.

[0058] FIGS. 13A and 13B depict an exemplary garment 100 in which additional vent pores 1302 are added to the first layer 104 and third layer 108 in the folded down portion of collar 1004. The entirety of collar 1004 may be formed from the same fabric and additional vent pores 1302 can be added to any portion of collar 1004, first layer 104, second layer 106, and third layer 108.

[0059] In the foregoing description, various features may be grouped together in a single embodiment for purposes of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claims require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated herein, with each claim standing on its own as a separate embodiment of this disclosure.

[0060] Moreover, it will be apparent to those skilled in the art from consideration of the specification and practice of the present disclosure that various modifications and variations can be made to the disclosed systems without departing from the scope of the disclosure, as claimed. Thus, it is intended that the specification and examples be considered as exemplary only, with a true scope of the present disclosure being indicated by the following claims and their equivalents.