KNITTED SPACER FABRIC WITH A PREDETERMINED SEPARATION POINT

Abstract

The invention relates to a knitted spacer fabric (10) comprising two layers (11, 12), which each comprise wales (15) running in a longitudinal direction (L) and courses (16) running in a transverse direction (Q). The two layers (11, 12) are arranged at a distance in a vertical direction (H) and are connected to one another by connection threads (26). In an exemplary embodiment a predetermined separation point (29) is formed in the longitudinal direction (L) between two directly adjacent separation point wales (15a, 15b) in each layer (11, 12). These two separation point wales (15a) are connected by a first thread bundle (20), which comprises fewer threads (22) than a second thread bundle (21). Additionally or alternatively, the wales (15) can comprise float portions (40), in which the threads (22) used for stitch formation outside the float portions (40) do not form any stitches. In the float portions (40), the connection threads (26) form connection thread stitches (42), in order to connect the edge stitches (41) of a wale (15) adjacent to the float portion (40).

Claims

1. A knitted spacer fabric (10) comprising: a first layer (11) comprising first layer first stitches (13) and first layer second stitches (14) and a second layer (12) comprising second layer first stitches (13) and second layer second stitches (14), forming wales (15) in a longitudinal direction (L) and forming courses (16) in a transverse direction (Q) at right angles to the longitudinal direction (L), wherein a thread loop of each of the first layer first stitches and the second layer first stitches (13) is formed by a first thread bundle (20) and a thread loop of each of the second layer first stitches and the second layer second stitches (14) is formed by a second thread bundle (21), wherein the first thread bundle (20), and the second thread bundle (21) are formed from a single thread (22) or a plurality of identical threads (22), which are arranged adjacently without direct connection, wherein the second thread bundle (21) comprises more threads (22) than the first thread bundle (20), wherein the first layer (11) and the second layer (12) are arranged at a distance from one another in a height direction (H) at right angles to the longitudinal direction (L) and the transverse direction (Q) and are connected to one another by connection threads (26), wherein in the first layer (11) and the second layer (12) there is provided at least one pair (27) formed of a first separation point wale (15a) and a second separation point wale (15b), which delimit therebetween a longitudinal gap (28) forming a predetermined separation point (29) and which are connected to one another by the first thread bundle (20) only, the wales (15) outside the predetermined separation point (29) being connected at least in part by the second thread bundle (21).

2. The knitted spacer fabric according to claim 1, wherein one or both of the first layer (11) or the second layer (12) are formed without weft threads.

3. The knitted spacer fabric according to claim 1, wherein the connection threads (26) do not cross a predetermined separation space (30), which is defined by pairs of the predetermined separation points (29) paired with one another in the first layer (12) and the second layer (12).

4. The knitted spacer fabric according to claim 1, wherein the connection threads (26) do not create a transverse connection between the first separation point wale (15a) of the first layer (11) and the second separation point wale (15b) of the second layer (12), and wherein the connection threads (26) do not create a transverse connection between the second separation point wale (15b) of the first layer (11) and the first separation point wale (15a) of the second layer (12).

5. The knitted spacer fabric according to claim 1, wherein the first thread bundle (20) comprises precisely one thread (22).

6. The knitted spacer fabric according to claim 1, wherein the second thread bundle (21) comprises precisely two threads (22).

7. The knitted spacer fabric according to claim 1, wherein all threads (22) of the first thread bundle (20) and of the second thread bundle (21) are made of a same material.

8. The knitted spacer fabric according to claim 1, wherein all threads (22) of the first thread bundle (20) and of the second thread bundle (21) have a same tensile strength.

9. The knitted spacer fabric according to claim 1, wherein all threads (22) of the first thread bundle (20) and of the second thread bundle (21) have a same thread structure.

10. The knitted spacer fabric according to claim 1, wherein the connection threads (26) are same as the at least one thread (22) of one or both of the first thread bundle (20) or of the second thread bundle (21).

11. The knitted spacer fabric according to claim 1, wherein several adjacently arranged wales (15) of the first layer (11) and of the second layer (12) each have a float portion (40), in which all of the first thread bundles (20) and the second thread bundles (21) run in the longitudinal direction without stitches.

12. The knitted spacer fabric according to claim 11, wherein two stitches (13, 14) adjoining the float portion (40) of each of the adjacently arranged wales (15) are connected to one another by connection thread stitches (42) of a respective connection thread of the connection threads (26) paired with a respective one of the adjacently arranged wales (15).

13. The knitted spacer fabric according to claim 12, wherein the connection thread stitches (42) are free from connections to an adjacent wale (15) of the adjacently arranged wales.

14. The knitted spacer fabric according to claim 11, wherein a gap between a first layer float portion (40) in the first layer (11) and a second layer float portion (40) in the second layer (12) paired with the first layer float portion (40) is free from connection threads (26) running between the first layer (11) and the second layer (12).

15. A knitted spacer fabric (10) comprising: a first layer (11) comprising first layer first stitches (13) and first layer second stitches (14) and a second layer (12) comprising second layer first stitches (13) and second layer second stitches (14), forming wales (15) in a longitudinal direction (L) and forming courses (16) in a transverse direction (Q) at right angles to the longitudinal direction (L), wherein the first layer (11) and the second layer (12) are arranged at a distance from one another in a height direction (H) at right angles to the longitudinal direction (L) and the transverse direction (Q) and are connected to one another by connection threads (26), wherein a plurality of wales (15) of the first layer (11) and a plurality of wales (15) of the second layer (12) arranged directly adjacently each comprise a float portion (40), in which threads (22) of the first layer (11) and the second layer (12) used for formation of stitches outside the float portion (40) do not form any stitches, wherein two stitches (13, 14) of each of the wales (15) adjacent to the float portion (40) are connected to one another by connection thread stitches (42) of a connection thread (26) paired with the wale (15) adjacent to the float portion (40).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Advantageous embodiments of the invention will become clear from the dependent claims, the description, and the drawings. Preferred exemplary embodiments of the invention will be explained in detail hereinafter on the basis of the accompanying drawings, in which:

[0038] FIG. 1 shows a basic schematic illustration of wales and courses of an exemplary embodiment of a knitted spacer fabric,

[0039] FIG. 2 shows a schematic perspective view of a stitch or thread loop formed on a first thread bundle,

[0040] FIG. 3 shows a schematic perspective view of a stitch or thread loop formed from a second thread bundle,

[0041] FIG. 4 shows a perspective illustration of an exemplary embodiment of connection threads running between a first layer and a second layer,

[0042] FIGS. 5 and 6 each show a heavily schematised illustration of an exemplary embodiment of a knitted spacer fabric, as considered in a longitudinal direction parallel to the wales,

[0043] FIG. 7 shows a schematic illustration of wales and courses of a layer of a knitted spacer fabric, wherein the wales each form a float portion,

[0044] FIG. 8 shows a perspective illustration of the extent of connection threads which are paired with the wales of the layout shown in FIG. 7, and

[0045] FIG. 9 shows a heavily schematised illustration of an exemplary embodiment of a knitted spacer fabric, as considered in a transverse direction Q parallel to the courses.

DETAILED DESCRIPTION

[0046] FIGS. 5 and 6 each show an exemplary embodiment of a knitted spacer fabric 10 in heavily schematised manner. The knitted spacer fabric 10 has a first layer 11 and a second layer 12. The first layer 11 and the second layer 12 are each formed by first stitches 13 and second stitches 14. The stitches 13, 14 form wales 15 in a longitudinal direction L and courses 16 in a transverse direction Q at right angles to the longitudinal direction L (FIG. 1).

[0047] In order to form the first stitches 13, a first thread bundle 20 is used, and in order to form the second stitches 14, a second thread bundle 21 is used. Each thread bundle 20, 21 comprises at least one thread 22 (FIGS. 2 and 3). The number of threads 22 of the second thread bundle 21 is greater than the number of threads 22 in the first thread bundle 20. The first thread bundle 20 is preferably formed by a single thread 22, and the second thread bundle 21 is preferably formed by two threads 22.

[0048] The threads used for all thread bundles 20, 21 in accordance with the example are made of the same material and preferably have the same thread thickness d or yarn count. In accordance with the example, each thread 22 can have a thread strength or yarn count of 11 dtex or more.

[0049] A plastics material is preferably used as material for the threads 22, for example polyester, polyamide or polypropylene. In the preferred exemplary embodiment all threads 22 of the two thread bundles 20, 21 have the same structure or are formed identically.

[0050] A plurality of threads 22 of a common thread bundle and in accordance with the example of the second thread bundle 21 are not directly connected to one another, but instead rest loosely against one another. The threads 22 in particular are not bonded to one another or intertwined or coupled directly to one another in another way.

[0051] As can be seen in FIG. 1, a first stitch 13 and a second stitch 14 alternate in the longitudinal direction L along a wale 15 and in the transverse direction Q along a course 16. In accordance with the example the first thread bundle 20 in each case forms in alternation a first stitch 13 in a wale 15 and then in the adjacent wale 15. Similarly, the second thread bundle 21 in each case forms in alternation a second stitch 14 in two directly adjacent wales 15. Two adjacent wales 15 are connected to one another either by a first thread bundle 20 or a second thread bundle 21. The wales 15 are thus connected to one another without use of an additional weft thread.

[0052] The weave shown by way of example in FIG. 1 serves merely for the purpose of explanation. Other weaves can also be used. FIG. 1 shows a view of the layers 11, 12 in the height direction H from the outside towards the knitted spacer fabric 10 according to FIGS. 5 and 6, i.e. towards the outer side facing away from the other layer 12 or 11 respectively.

[0053] The two layers 11, 12 are connected to one another by connection threads 26, which are shown in a perspective view by way of example in FIG. 4 and merely in a heavily schematised manner in FIGS. 5 and 6.

[0054] In the height direction H, the first layer 11 and the second layer 12 of the knitted spacer fabric 10 are arranged at a predefined distance from one another, which can vary depending on the desired thickness of the knitted spacer fabric 10. The connection threads 26 are incorporated in the stitches 13, 14 of the two paired wales 15 in the first layer 11 and the second layer 12.

[0055] In the exemplary embodiment shown here, the connection threads each form rows arranged in the longitudinal direction L between a wale 15 of the first layer 11 and a wale 15 of the second layer 12. A connection thread 26 consequently runs substantially in a plane spanned by a height direction H and the longitudinal direction L.

[0056] In each layer 11, 12, there is provided at least one pair 27 formed of a first separation point wale 15a and a second separation point wale 15b, which therebetween delimit a longitudinal gap 28 in the transverse direction Q. The first separation point wale 15a and the second separation point wale 15b are connected to one another in this longitudinal gap 28 exclusively by the first thread bundle 20, such that a predetermined separation point 29 is thus formed. The predetermined separation point 29 extends between the first separation point wale 15a and the second separation point wale 15b in the longitudinal direction L along the layer 11 or 12.

[0057] As can be seen in FIGS. 5 and 6, a predetermined separation point 29 in the first layer 11 and a predetermined separation point 29 in the second layer 12 are arranged in alignment with one another in the height direction H. Alternatively, the predetermined separation points 29 in the first layer 11 and in the second layer 12 could be offset in the transverse direction Q. A predetermined separation space 30 is defined between the two predetermined separation points 29 paired with one another, with no connection threads 26 extending through said space. The connection threads 26 extend in the transverse direction Q adjacently to the predetermined separation space 30.

[0058] In the exemplary embodiment shown in FIG. 5, pairs 27 formed of a first separation point wale 15a and a second separation point wale 15b, arranged adjacently in the transverse direction, are in each case connected to one another by a second thread bundle 21. This connection is more stable and resistant to tearing than the connection at the corresponding predetermined separation point 29. The number of predetermined separation points 29 can vary. In the exemplary embodiment shown in FIG. 6 four wales 15 are in each case connected to one another by a second thread bundle 21, wherein in each case two adjacent blocks formed of four wales 15 are connected to one another at the predetermined separation points 29 exclusively by a first thread bundle 20.

[0059] In the exemplary embodiment according to FIGS. 1-6, it is possible for the reinforcement thread 26 to use the same thread 22 as is used also for the thread bundles 20, 21.

[0060] In FIGS. 7-9 the structure of a further exemplary embodiment of a knitted spacer fabric 10 is shown schematically in a first layer 11 and a second layer 12. The stitches and the layers 11, 12 can be formed by first stitches 13 and second stitches 14, as has been described above. Alternatively, it is also possible in the exemplary embodiment according to FIGS. 7-9 for all stitches to use the same thread bundle 20 or 21, such that all stitches are formed either merely by first stitches 13 or merely by second stitches 14.

[0061] In contrast to the previous exemplary embodiment, at least one float portion 40 is formed both in the first layer 11 and in the second layer 12 in each provided wale 15. In a float portion 40, the at least one thread 22 does not form a stitch and runs substantially in the longitudinal direction L, wherein it can have a certain undulation depending on the thread tension. In accordance with the example both the first thread bundle 20 and the second thread bundle 21 do not have any stitches in respective float portions 40. Each wale 15 has a stitch 13 or 14 adjacently to the float portion 40, which stitch can be referred to as an edge stitch 41.

[0062] The two edge stitches 41 of each wale 15 are connected by the first or second thread bundles 20 or 21 extending in a stitch-free manner in the float portion 40. In order to maintain the stitch structure in the wale 15, the two edge stitches 41 are additionally connected to one another by one or more connection thread stitches 42 of an associated connection thread 26. Connection threads 26 which form connection thread stitches 42 in one of the two layers 11 or 12 for the corresponding wale 15 are shown in FIG. 8. These connection thread stitches 42 are provided in the float portions 40 both in the first layer 11 and in the second layer 12, which is shown in a heavily schematised manner in FIG. 9. It can be seen in FIG. 9 that the float portions 40 in the first layer 11 arranged adjacently in the transverse direction Q and forming a float region 40 and the float portions 40 in the second layer 12 arranged adjacently in the transverse direction Q and forming a float region are arranged at least partially overlapping and preferably congruently, such that a gap is provided in the height direction H between float regions, which gap forms a free space 43, which is not penetrated by reinforcement threads 26. The free space 43 extends in the longitudinal direction L along the float portions 40 or float regions in the two layers 11, 12 and in the transverse direction Q along all wales 15 having a float portion 40.

[0063] The free space 43 can extend preferably completely in the transverse direction Q through the knitted spacer fabric 10 (if the float region in the transverse direction Q is as wide as the knitted spacer fabric 10), but in another exemplary embodiment can also have a dimension in the transverse direction Q smaller than the total width of the knitted spacer fabric 10. A predetermined separation point of the knitted spacer fabric 10 in the transverse direction Q is formed by the float portions 40 and the free space 43.

[0064] The connection thread stitches 42 in accordance with the example connect merely the edge stitches 41 of a single wale and within the float portions 40 do not have any connection to adjacent wales 15.

[0065] The connection threads 26 in the exemplary embodiment according to FIGS. 7-9 have a tear strength or tensile strength lower than that of the threads used for stitch formation in the wales 15 outside the float portions 40, and in accordance with the example lower than that of the at least one thread 22.

[0066] The invention relates to a knitted spacer fabric 10 comprising two layers 11, 12, which each comprise wales 15 running in a longitudinal direction L and courses 16 running in a transverse direction Q. The two layers 11, 12 are arranged at a distance in a vertical direction H and are connected to one another by connection threads 26. In an exemplary embodiment a predetermined separation point 29 is formed in the longitudinal direction L between two directly adjacent separation point wales 15a, 15b in each layer 11, 12. These two separation point wales 15a are connected by a first thread bundle 20, which comprises fewer threads 22 than a second thread bundle 21. Additionally or alternatively, the wales 15 can comprise float portions 40, in which the threads 22 used for stitch formation outside the float portions 40 do not form any stitches. In the float portions 40, the connection threads 26 form connection thread stitches 42, in order to connect the edge stitches 41 of a wale 15 adjacent to the float portion 40.

LIST OF REFERENCE SIGNS

[0067] 10 knitted spacer fabric [0068] 11 first layer [0069] 12 second layer [0070] 13 first stitch [0071] 14 second stitch [0072] 15 wale [0073] 15a first separation point wale [0074] 15b second separation point wale [0075] 16 course [0076] 20 first thread bundle [0077] 21 second thread bundle [0078] 22 thread [0079] 26 connection thread [0080] 27 pair [0081] 28 longitudinal gap [0082] 29 predetermined separation point [0083] 30 predetermined separation space [0084] 40 float portion [0085] 41 edge stitch [0086] 42 connection thread stitch [0087] 43 free space [0088] d thread thickness [0089] H height direction [0090] L longitudinal direction [0091] Q transverse direction