GB2625631A

GB2625631A - Fabric

Info

Publication number: GB2625631A
Application number: GB2316568.1A
Authority: GB
Inventors: Nicholas Travell Geoffrey
Original assignee: Planet Knox Ltd
Current assignee: Planet Knox Ltd
Priority date: 2022-10-31
Filing date: 2023-10-30
Publication date: 2024-06-26
Also published as: GB202316568D0; GB202216152D0

Abstract

A fabric 10 for the manufacture of protective garments includes a first face 12 including a first material 18 and a second face 14 including a second material 20. The second material 20 is different to the first material 18. The first face 12 and the second face 14 are knitted together with a third material 16. The first material 18 is a textile material. The textile material includes a composite material having natural and synthetic material fibres. The second material 20 is a protective material. The third material 16 includes an elastomeric material.

Description

FABRIC

This invention relates generally to a fabric. More specifically although not exclusively, this invention relates to a fabric for incorporation into a garment, for example a protective garment or item of clothing. The invention also relates to a protective garment including the fabric.

BACKGROUND

Protective garments and clothing items provide impact and/or other protection to the wearer of the garment. Protective clothing is worn by motorcycle users, cyclists and skiers, as well as security personnel, for example police and prison officers. Protective clothing for motorcycle riders is designed to protect the rider from serious injury in the event of an accident, for example impact with and abrasion from the riding surface, without significantly reducing the rider's ability to control the motorcycle.

It is understood that if a rider is comfortable, they are more likely to be able to concentrate properly. It is, therefore, also desirable for clothing for motorcycle riders to be designed to protect the rider from weather conditions and fit well.

It would therefore be advantageous to provide a fabric for protective clothing which meets (or exceeds) the required safety standards and from which comfortable clothing can be manufactured.

BRIEF SUMMARY OF THE DISCLOSURE

Accordingly, an aspect of the invention provides a fabric for protective garments, for example a fabric suitable for the manufacture of protective garments.

The fabric may be a double-faced fabric. The fabric may, for example include a first face including a first material and a second face including a second material. The first material may be different to the second material. The first face may be an outer face of the fabric.

The second face may be an inner face of the fabric.

The fabric may be a knitted fabric. The fabric may, for example, include a first face and a second face, wherein the first face and the second face are knitted together with a third material. The third material may include an elastomeric material.

Advantageously, the fabric is resistant to damage caused by abrasion and/or cutting, yet can be manufactured into garments and is comfortable to wear by virtue of the synergistic effect of the different materials and the way they are knitted together into a double-faced fabric.

Another aspect of the invention provides a fabric for protective garments, the fabric comprising a first face including a first material; and a second face including a second material, which second material is different to the first material; wherein the first face and the second face are knitted together with a third material; and wherein the third material o comprises an elastomeric material.

The fabric is resistant to damage caused by abrasion and/or cutting, yet can be manufactured into garments and is comfortable to wear by virtue of the synergistic effect of the different materials and the way they are knitted together into a double-faced fabric.

The third material may, for example, comprise elastane. The third material may include one or more yarns of elastane.

The second material may comprise a protective or technical material, for example a high-performance polymer. By protective or technical material, we mean a material which has physical properties which provide protection against external influences for example heat, chemicals, mechanical hazards and/or severe or harsh weather conditions.

The high-performance polymer may be a thermoplastic polyethylene, for example ultra-high molecular weight polyethylene (also referred to as high-modulus polyethylene). The second material may include on one or more yarns of the high-performance polymer, for example one or more yarns of ultra-high molecular weight polyethylene. The one or more yarns of the high-performance polymer, e.g. the one or more yarns of ultra-high molecular weight polyethelene, may have a linear mas density of at least 200 denier. The one or more yarns of the high-performance polymer, e.g. the one or more yarns of ultra-high molecular weight polyethelene, may have a linear mass density of up to 400 denier. In a preferred embodiment of the invention, the one or more yarns of ultra-high molecular weight polyethelene may have a linear mass density of approximately 220 denier.

The first material may comprise a textile material. The first material may comprise one or more yarns of a textile material. By textile material we mean a fibre or yarn-based based material which may be used in the manufacture of consumer fabrics, for example clothing.

The textile material may comprise any one of a natural material, a synthetic (or man-made) material and a composite material including natural and synthetic (or man-made) material fibres. The first material may, for example, comprise cotton or wool. Alternatively, the first material may comprise any one of nylon, polyester and acrylic. The first material may include an inorganic material, e.g. carbon, ceramic, glass or metal. The first material may io include an organic material, for example an organic material formed by the transformation of natural polymers, e.g. acetate, triacetate, alginate, cupro, elastodiene, rubber, Lyocell, Modal or viscose. The first material may include an organic material, for example an organic material formed from a synthetic polymer, e.g. acrylic, modacrylic, aramid, chlorofibre, elastane, elastodiene, fluorofibre, polyamide, polyimide, polyester, polyethylene, polypropylene or vinyl. In some examples, the first material may comprise a cotton and polyester composite material, for example a polycotton.

The fabric may be an interlock knitted fabric. The first face may be an outer face of the fabric. The second face may be an inner face of the fabric.

The fabric may comprise at least 30 weight % of the first material. The fabric may comprise up to 80 weight % of the first material. The fabric may comprise at least 20 weight % of the second material. The fabric may comprise up to 70 weight % of the second material. The fabric may comprise at least 2 weight cro of the third material. The fabric may comprise up to 10 weight c/o of the third material. The fabric may, for example comprise 48 weight % of the first material, 48 weight cro of the second material and 4 weight % of the third material. Alternatively, the fabric may comprise 30 weight % of the first material, 60 weight % of the second material and 10 weight % of the third material. By weight %, we mean the weight % of that component in the finished fabric grams per square metre (g/m2 or GSM).

The fabric may meet or exceed the protective regulatory requirements of EN 17092-2020 for class A, class AA, and/or class AAA garments, for example the regulatory requirements for tear strength and/or for seam strength and/or for abrasion and tear resistance. The fabric may, for example, have a tear strength of at least 50 N. Additionally or alternatively, the fabric may have a seam strength of at least 12 N/mm. Additionally or alternatively, the fabric may have a coefficient of friction of at least 0.5, for example at least 0.6, preferably at least 0.7.

Another aspect of the invention provides a fabric for protective garments, the fabric comprising a first face including a first, textile, material, the first, textile, material comprising a composite material including natural and synthetic material fibres; and a second face including a second, protective, material, which second, protective, material is different to the first material; wherein the first face and the second face are knitted together with a third material; and wherein the third material comprises an elastomeric material.

The second, protective, material may comprise a technical material, for example a high-performance polymer. By protective or technical material, we mean a material which has physical properties which provide protection against external influences for example heat, chemicals, mechanical hazards and/or severe or harsh weather conditions.

The first, textile, material may comprise one or more yarns of a textile material. By textile material we mean a fibre or yarn-based based material which may be used in the manufacture of consumer fabrics, for example clothing.

The textile material comprises a a composite material including natural and synthetic (or man-made) material fibres. The first material may, for example, comprise cotton or wool. The first material may additionally include an organic material, for example an organic material formed from a synthetic polymer, e.g. acrylic, modacrylic, aramid, chlorofibre, elastane, elastodiene, fluorofibre, polyamide, polyimide, polyester, polyethylene, io polypropylene or vinyl. In some examples, the first material may comprise a natural material, e.g. cotton, and an organic material, e.g. polyester. The first material may include a composite material, for example a composition material including polyester and cotton, e.g. polycotton.

The fabric may comprise at least 30 weight % of the first material. The fabric may comprise up to 80 weight % of the first material. The fabric may comprise at least 20 weight % of the second material. The fabric may comprise up to 70 weight % of the second material. The fabric may comprise at least 2 weight % of the third material. The fabric may comprise up to 10 weight % of the third material.

The fabric may include between approximately 30 weight % and approximately 80 weight % of the first material.

The fabric may include between approximately 20 weight % and approximately 70 weight % of the second material.

The fabric may include between approximately 2 weight % and approximately 10 weight % of the third material.

The first material may include between approximately 5 weight % and approximately 50 weight % natural material fibres. The first material may include between approximately 5 weight % and approximately 50 weight % cotton, for example cotton fibres.

The first material may include between approximately 10 weight % and approximately 70 weight % synthetic material fibres. The first material may include between approximately weight % and approximately 70 weight % polyester, for example polyester fibres.

The first material may be a composite material.

The composite material may include a blend of natural and synthetic fibres. The natural fibres may be cotton fibres. The synthetic fibres may be polyester fibres. The composite material may include between 1 weight % and 99 weight °h. polyester fibres. The composite material may include between 1 weight cro and 99 weight % cotton fibres. The composite material may, for example include approximately 20 weight % cotton and approximately 80 weight % polyester. The composite material may include approximately 40 weight % cotton and approximately 60 weight I% polyester. The composite material may include approximately 50 weight % cotton and approximately 50 weight % polyester.

The fabric may comprise between approximately 5 weight % and approximately 50 weight % cotton. The fabric may comprise between approximately 10 weight % and approximately 70 weight % polyester.

In one example, the fabric may include 80 weight r%. of the first material, 18 weight % of the second material and 2 weight % of the third material. The first material may be a composite material.

The composite material may comprise 50 weight % polyester and 50 weight percent cotton.

In other words, the fabric may comprise 40 weight c/o polyester and 40 weight % cotton.

The composite material may comprise 20 weight % cotton and 80 weight % polyester. In other words, the fabric may comprise 16 weight % cotton and 64 weight % polyester.

The composite material may comprise 40 weight % cotton and 60 weight % polyester. In other words, the fabric may 32 weight % cotton and 48 weight % polyester.

In another example, the fabric may include 48 weight % of the first material, 48 weight % of the second material and 4 weight % of the third material. The first material may be a composite material.

The composite material may comprise 50 weight % polyester and 50 weight percent cotton. In other words, the fabric may comprise 24 weight % polyester and 24 weight % cotton. The composite material may comprise 20 weight % cotton and 80 weight % polyester. In other words, the fabric may comprise 9.6 weight % cotton and 38.4 weight % polyester.

The composite material may comprise 40 weight % cotton and 60 weight % polyester. In other words, the fabric may comprise 19.2 weight % cotton and 28.8 weight % polyester.

In an alternative example, the fabric may include 30 weight I% of the first material, 60 weight % of the second material and 10 weight % of the third material. The first material may be a composite material.

In other words, the fabric may comprise 15 weight % polyester and 15 weight % cotton.

The composite material may comprise 20 weight % cotton and 80 weight % polyester. In other words, the fabric may comprise 6 weight % cotton and 24 weight % polyester.

The composite material may comprise 40 weight % cotton and 60 weight % polyester. In other words, the fabric may comprise 12 weight % cotton and 18 weight % polyester.

By weight %, we mean the weight % of that component in the finished fabric grams per square metre (g/m2 or GSM).

The fabric may be a protective fabric. The fabric may be a protective garment fabric.

According to another aspect of the invention there is provided a protective garment including the fabric according to the preceding aspects of the invention. The protective garment may, for example, be a protective garment for a rider of a motorcycle.

The first face of the fabric may be an outer face of the fabric. In this way the first face may be part of, or form, an outer face or layer of the protective garment. In other words, the first face of the fabric may face away from or outward compared to the body of a person wearing o the protective garment.

The second face of the fabric may be an inner face of the fabric. In this way the second face may be part of, or form, an inner face or layer of the protective garment. In other words, the second face of the fabric may face toward or inward compared to the body of a person wearing the protective garment For the avoidance of doubt, any of the features described herein apply equally to any aspect of the invention. For example, the garment may comprise any one or more features of the fabric relevant to the garment.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. For the avoidance of doubt, the terms "may", "and/or", "e.g.", "for example" and any similar term as used herein should be interpreted as non-limiting such that any feature so-described need not be present. Indeed, any combination of optional features is expressly envisaged without departing from the scope of the invention, whether or not these are expressly claimed. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings in which: Figure 1 is a first plan view of a fabric according to an embodiment of the invention; Figure 2 is a second plan view of the fabric of Figure 1; Figure 3 is a schematic representation of a side view of the fabric of Figure 1; Figure 4a is a schematic representation of the yarns or materials of the fabric of Figure 1; Figure 4b is an exploded view of a portion of the schematic representation of Figure 4a; Figure 5 shows an upper body garment including a fabric in accordance with an aspect of the present invention; and Figure 6 shows a lower body garment including a fabric in accordance with an aspect of the present invention.

DETAILED DESCRIPTION

Referring now to Figures 1, 2 and 3, there is shown a swatch or portion of a fabric 10 according to an example of the present invention. The fabric 10 is a double-faced fabric and has a first face 12 and a second face 14.

The first face 12 includes one or more yarns or fibres of a first material 18 (as shown in Figures 4a and 4b). The first material 18 is a textile material, which could be any one of any one of a natural material (e.g. cotton), a synthetic material (e.g. nylon polyester or acrylic) and a composite material including natural and synthetic material fibres (e.g. a polyester-cotton composite material, such as that referred to as polycotton). In this example of the invention, the first, or textile, material 18 is cotton.

The second face 14 includes one or more yarns or fibres of a second material 20 (as shown in Figures 4a and 4b). The second material 20 is a protective or technical material in the form of a high-performance polymer. Examples of suitable high-performance polymers include thermoplastic polyethylene. In this example of the invention, the second material 20 is ultra-high molecular weight polyethylene. The one or more yarns of the ultra-high molecular weight polyethylene in this example have a linear mass density of 220 denier.

The fabric 10 also includes a third material 16. The third material 16 is an elastomeric material, for example a polyether-polyurea copolymer known as spandex or elastane or Lycra®. In this example of the intention, the third material 16 is elastane.

The fabric 10 is manufactured by knitting, such that the cotton first face 12, the ultra-high molecular weight polyethylene second face 14 and the elastane third material are interlocked, as shown in Figures 4a and 4b. The applicant has surprisingly found that, despite the strength of ultra-high molecular weight polyethylene and the elasticity of the elastane, the two yarns can be knitted with cotton to form a fabric 10 with protective properties and stretch, as will be described further below.

In particular, the fabric 10 can be knitted on a circular knitting machine with two sets of needles, a first set for the yarn of the cotton first material 18 and a second set for the yarn of the ultra-high molecular weight polyethylene second material 20. The elastane third material 16 is fed into the knitting machine via a third direct line. The fabric 10 is thus knitted in tubular form. The fabric 10 is then split to provide a fabric of the desired width and finished. Suitable methods for finishing the fabric would be known to the person skilled in the art.

In this way, the cotton first face 12 and the ultra-high molecular weight polyethylene second face 14 are interlocked with the elastane third material 16. The resulting fabric 10 has a first face 12 which resembles a 'normal' cotton fabric and a second face 14 which is made from a material which is particularly strong and resistant to abrasion. The incorporation of the elastane third material 16 enables the material to stetch, making the fabric 10 particularly suitable for manufacturing garments.

The relative proportions of each of the cotton first material 18, the ultra-high molecular weight polyethylene second material 20 and the elastane third material 16 can be varied according to the requirements of the fabric 10. In one example, the fabric 10 includes 48% cotton, 48% ultra-high molecular weight polyethylene and 4% elastane. In an alternative example, the fabric 10 includes 30% cotton, 60% ultra-high molecular weight polyethylene and 10% elastane.

The tear strength of the fabric 10 was tested in accordance with the procedure described in EN 17092-1:2020, EN ISO 3377-1:2011 and EN ISO 4674-1:2016, method B. Five samples of the fabric 10 were tested in each of the warp (or lengthwise or longitudinal) and weft (or transverse) directions. The test pieces were each 200 mm long and 50 mm wide. A longitudinal slit 100 mm in length was made in each test piece, beginning from the middle of the width. A mark was made 25 mm from the uncut end in the middle of the strip to io indicate the position of the end of the tear on completion of the test. The test pieces were clamped symmetrically in the jaws of a test machine such that one 'leg' was held in each jaw and the uncut end of the fabric piece remained free. Each leg was fixed such that the beginning of the tear was parallel to the direction in which the tearing force was applied. The test machine was adjusted to give a rate of jaw traverse of 100 mm / min± 10 mm / min at an appropriate load capacity range. The tear force was calculated in accordance with the procedures described in EN ISO 4674-1:2016, section 7.3. In each case, the tear strength of the fabric 10 was found to exceed 50 N. The seam strength of the fabric 10 was tested according the procedure described in EN 17092-1:2020 and EN 13594:2015, 6.7 and Annex B. Three test pieces were prepared and tested in a tensile testing machine with a range of 0 n to 2 kN and a rate of traverse of 100 mm / mm ± 20 mm / min. The seam strength was calculated by dividing the breaking force (N) by the length of the tested seam (mm). In each case, the seam strength of the fabric 10 was found to exceed 12 N/mm.

The impact abrasion resistance of the fabric 10 was tested in accordance with EN 170921:220 using the Darmstadt method.

The test procedure simulates the stress that is put on protective garments of an average rider with a body mass of 75 kg and a height of 1.75 m when sliding from variable initial speeds to standstill on a real concrete road surface. Three samples of the material were mounted in sample holders attached to three arms of a rotating sample carrier positioned above a concrete tile (which emulated a concrete road surface). An electric motor accelerated the rotor to 707 revolutions per minute, with the samples not yet touching the concrete file. After reaching 120 km per hour, the motor was switched off and the rotor was released to fall onto the concrete tile. As in a real accident, after touching the concrete tile surface, friction forces between the test samples and the concrete tile decelerate the rotor until it stops. Nine identical material test samples were tested during three test runs, completing one test cycle. After each test run of the test cycle, the samples were assessed for hole formation. In each case, it was found that no holes were formed through the thickness of the fabric 10. The fabric samples were tested in the warp direction, the weft direction and at 45° to the warp and weft directions. In each case, the coefficient of friction of the fabric was found to be greater than 0.5. In some examples, the fabric 10 was found to have a coefficient of friction of more than 0.7, e.g. 0.76. The fabric 10 was therefore io found to have passed the requirements of the abrasion resistance test.

Without wishing to be bound by theory, it is believed that the damage caused to the first, textile, face 12 by the initial friction forces acting between the fabric 10 and the concrete during deceleration enables the dissipation of heat. This prevents the second, ultra-high molecular weight polyethylene, face 14 melting, maintains the physical integrity of the second face 14, and ensures that the second face 14 of the fabric 10 is resistant to impact abrasion. In other words, the inventor has surprisingly found that the first, textile, face acts as a sacrificial layer protecting the second face from damage.

The protective properties and stretch of the fabric 10 make it suitable for use in the manufacture of protective garments, for example protective garments, such as the upper body garment 30a (as shown in Figure 5) and the protective lower body garment 30b (as shown in Figure 6). The garments can be made using conventional methods.

Figure 5 shows an upper body garment 30a, such as a jacket, having a pair of shoulder regions 32, and a pair of elbow regions 34. The entire upper body garment 30a may be manufactured from the fabric 10. Alternatively, the protective fabric 10 may be used for one or more regions 38 of the garment 30a where additional protection is required, for example one or more of the pair of shoulder regions 32 and/or one or more of the pair of elbow regions 34.

Figure 6 shows a lower body garment 30b, such as a pair of trousers, that includes a pair of knee regions 36. As described in relation to the upper body garment 30a, the entire upper body garment 30a may be manufactured from the fabric 10. Alternatively, the protective fabric 10 may be used for one or more regions 38 of the garment 30b where extra protection is required, for example one or more of the pair of knee regions 36.

Whilst the invention has been described in relation to protective fabrics for garments for riders of motorcycles, it will be understood that the fabric could be used for the manufacture of protective garments for other applications. The fabric could be used, for example, in the manufacture of garments or clothing where resistance to abrasion and/or slashing and/or cutting is desirable or necessary. Garments made from the fabric of this invention may be worn by riders of bicycles or scooters, e.g. electric scooters and/or skiers, and/or security personnel, for example people working in the police or for the prison service.

Whilst the fabric 10 is described as including a cotton first face 12, it will be understood that the first face of the fabric 10 may include a composite material, for example a composite material including fibres of a natural material and fibres of a synthetic material. The composite material may include cotton and polyester, e.g. polycotton.

Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

It will be appreciated by those skilled in the art that several variations to the aforementioned embodiments are envisaged without departing from the scope of the invention For

example,

It will also be appreciated by those skilled in the art that any number of combinations of the aforementioned features and/or those shown in the appended drawings provide clear advantages over the prior art and are therefore within the scope of the invention described herein.

Throughout the description and claims of this specification, the words "comprise" and "contain" and variations of them mean "including but not limited to", and they are not intended to (and do not) exclude other moieties, additives, components, integers or steps. Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, ro unless the context requires otherwise.

The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

Claims

CLAIMSA fabric for the manufacture of protective garments, the fabric comprising: a first face including a first, textile, material, the first, textile, material comprising a composite material including natural and synthetic material fibres; and a second face including a second, protective, material, which second, protective, material is different to the first material; wherein the first face and the second face are knitted together with a third material; and wherein the third material comprises an elastomeric material.
A fabric according to claim 1, wherein the third material comprises elastane.
A fabric according to claim 1 or claim 2, wherein the second, protective, material is a high-performance polymer.
A fabric according to claim 3, wherein the high-performance polymer is a thermoplastic polyethylene, for example ultra-high molecular weight polyethylene.
5. A fabric according to any one of claims 1 to 4, wherein the first, textile, material comprises cotton.
A fabric according to any one of claims 1 to 5, wherein the first, textile, material comprises any one of nylon, polyester and acrylic.
7. A fabric according to any one of claims 1 to 6, wherein the fabric is an interlock knitted fabric.
A fabric according to any one of claims 1 to 7, wherein the fabric comprises between approximately 30 weight % and approximately 80 weight % of the first material.
A fabric according to any of claims 1 to 8, wherein the fabric comprises between approximately 20 weight cro and approximately 70 weight % of the second material.
10. A fabric according to any of claims 1 to 9, wherein the fabric comprises between approximately 2 weight % and approximately 10 weight % of the third material.
11 A fabric according to any one of claims 1 to 10, wherein the first material comprises between approximately 5 weight % and approximately 50 weight I% natural material fibres.
12. A fabric according to any one of claims 1 to 11, wherein the first material comprises between approximately 10 weight % and approximately 70 weight % synthetic io material fibres.
13. A fabric according to any one of claims 1 to 12, wherein fabric has a tear strength of at least 50 N.
14. A fabric according to any one of claims 1 to 13, wherein the fabric has a seam strength of at least 12N/mm.
15. A fabric according to any one of claims 1 to 14, wherein the fabric has a coefficient of friction of at least 0.5.
16. A fabric according to any one of claims 1 to 15, wherein the fabric has a coefficient of friction of at least 0.7.
17. A protective garment including the fabric according to any one of claims 1 to 16.
18. A protective garment according to claim 17, wherein the protective garment is a protective garment for a rider of a motorcycle.