WO2019147794A1

WO2019147794A1 - Cooling material

Info

Publication number: WO2019147794A1
Application number: PCT/US2019/014932
Authority: WO
Inventors: Eugene Alletto, Jr.
Original assignee: Bedgear, Llc
Priority date: 2018-01-29
Filing date: 2019-01-24
Publication date: 2019-08-01
Also published as: US20190249343A1; US20220178054A1

Abstract

A cooling material (10) includes opposite top (12) and bottom (14) surfaces and a central portion (16) positioned between the top (12) and bottom (14) surfaces. The top surface (12) includes a first fiber (18). The bottom surface (14) includes a second fiber (20). The middle portion (16) includes the first (18) and second (20) fibers and a third fiber (22).

Description

COOLING MATERIAL

TECHNICAL FIELD

[0001 ] The present disclosure generally relates to cooling materials, and more particularly to materials having cooling effects. Methods of manufacture are included

BACKGROUND

[0002] Sleep is critical for people to feel and perform their best, in every aspect of their lives. Sleep is an essential path to better health and reaching personal goals. Indeed, sleep affects everything from the ability to commit new information to memory to weight gain. It is therefore essential for people to use bedding that suit both their personal sleep preference and body type in order to achieve comfortable, restful sleep.

[0003] Selecting the appropriate type of bedding is an important aspect in achieving proper sleep. For example, selecting a pillow, mattress, mattress topper, etc. that is cool to the touch can greatly affect how comfortable a user is when they sleep. Indeed, materials that are cool to the touch may prevent the user from overheating while he or she is sleeping and/or can create a comfortable environment to allow the user to fall asleep more quickly. However, conventional materials used to make bedding are not cool to the touch, thus causing the sleeper discomfort, which can prevent restful sleep. This disclosure describes an improvement over these prior art technologies.

SUMMARY

[0004] In one embodiment, in accordance with the principles of the present disclosure, a cooling material is provided that includes opposite top and bottom surfaces and a central portion positioned between the top and botom surfaces. The top surface comprises a first fiber. The bottom surface comprises a second fiber. The middle portion comprises the first and second fibers and a third fiber.

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] The present disclosure will become more readily apparent from the specific description accompanied by the following drawings, in which:

[0006] FIG. 1 is a front view of one embodiment of a cooling material in accordance with the present principles of the present disclosure;

[0007] FIG. 2 is a back view of one embodiment of the cooling material shown in FIG. 1 ;

[0008] Fig. 3 is a chart providing information on Yarn Content, Yarn

Specifications and G-Max(W/cm²} of one embodiment of a cooling material in accordance with the present principles of the present disclosure; and

[0009] Fig. 4 is a chart providing information on Yarn Content, Yam

Specifications and Melange Effect of one embodiment of a cooling material in accordance with the present principles of the present disclosure; and

[0010] Fig. 5 is a chart of example yarns shortlisted based on Qmax and Melange Effect.

DETAILED DESCRIPTION

[0011] The exemplary embodiments of cooling materials and methods of making cooling materials are discussed in terms of cooling materials for use in bedding, such as, for example, pillows, mattresses, mattress toppers, etc. The present disclosure may be understood more readily by reference to the following detailed description of the disclosure. It is to be understood that this disclosure is not limited to the specific devices, methods, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed disclosure. [0012] Also, as used in the specification and including the appended claims, the singular forms“a,”“an,” and“the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from“about” or “approximately” one particular value and/or to “about” or“approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent“about,” it will be understood that the particular value forms another embodiment. It is also understood that all spatial references, such as, for example, horizontal, vertical, top, upper, lower, bottom, left and right, are for illustrative purposes only and can be varied within the scope of the disclosure. For example, the references“upper” and“lower” are relative and used only in the context to the other and are not necessarily“superior and“inferior”.

[0013] The following discussion includes a description of cooing material 10 The components of material 10 can be fabricated from materials including polymers and/or composites, depending on the particular application. For example, material 10 can be fabricated from materials such as fabrics or textiles, paper or cardboard, cellulosic-based materials, biodegradable materials, plastics and other polymers, semi-rigid and rigid materials. Material 10 may also be fabricated from a heterogeneous material such as a combination of two or more of the above-described materials. Material 10 and/or components of material 10 can be extruded, molded, injection molded, cast, pressed and/or machined.

[0014] Material 10 comprises a yarn that is extruded through spinnerets by adding flakes or pellets of a cooling substance, such as, for example, mica to flakes or pellets of raw material(s). Mica is the name of potassium, magnesium, iron, aluminum, lithium and other family layered silicate minerals. It is widely distributed on the earth and is one of the familiar minerals in daily life. It has stable chemical property and good thermal conductivity, water absorption, adsorption property. Due to the thermal conductivity of 0.03, its transfer rate is 5 times higher than the polyester. Mica’s excellent thermal conductivity is mainly due to its layer structure. It has been found that good heat conducting mica fiber textiles can rapidly transferred body heat to the outside of fabric, and it is very suitable for spring and summer cooling product. Other cooling minerals e.g. cooling Jade can also be added. The flakes or pellets of the cooling substance are melted together with the flakes or pellets of the raw material(s) and as the filaments come out of the spinneret, they are cooled. The cooling process solidifies them and turns them into filaments. In some embodiments, the raw material(s) is/are rayon, nylon and/or polyester. In some embodiments, the raw materiai(s) is/are uncrimped rayon filaments, uncrimped nylon filaments and/or uncrimped polyester filaments. For example, in one embodiment, material 10 includes a“cooling nylon” yarn wherein flakes or pellets of mica are added to flakes or pellets of nylon. The mica flakes or pellets are melted with the flakes or pellets of nylon to form a composition that is extruded through a spinneret to form the cooling nylon yarn as described above.

[0015] In one embodiment, material 10 comprises a“cooling rayon” yam wherein flakes or pellets of mica are added to flakes or pellets of rayon. The mica flakes or pellets are melted with the flakes or pellets of rayon to form a composition that is extruded through a spinneret to form the cooling rayon yarn containing up to about 60% by weight of mica flakes or pellets. In alternative embodiments of the rayon composition of the present invention comprises about 0.1 % to about 50% by weight of mica flakes or pellets, about 0.1 % to about 45% by weight of mica flakes or pellets, about 0.1 % to about 40% by weight of mica flakes or pellets, about 0.1 % to about 35% by weight of mica flakes or pellets, about 0.1 % to about 30% by weight of mica flakes or pellets, about 0.1 % to about 25% by weight of mica flakes or pellets, about 0.1 % to about 20% by weight of mica flakes or pellets, about 0.1 % to about 15% by weight of mica flakes or pellets; about 0.1 % to about 10% by weight of mica flakes or pellets; about 0.1 % to about 5% by weight of mica flakes or pellets, about 0.1 % to about 2% by weight of mica flakes or pellets or any combinations thereof.

[0016] In one embodiment, material 10 comprises a“cooling polyester” yarn wherein flakes or pellets of mica are added to flakes or pellets of polyester. The mica flakes or pellets are melted with the flakes or pellets of polyester to form a composition that is extruded through a spinneret to form the cooling polyester yarn thread once cooled. The mica flakes or pellets are melted with polyester to form a composition that is extruded through a spinneret to form the cooling polyester yarn containing up to about 60% by weight of mica flakes or pellets. In alternative embodiments of the polyester composition of the present invention comprises about 0.1 % to about 50% by weight of mica flakes or pellets, about 0.1 % to about 45% by weight of mica flakes or pellets, about 0.1 % to about 40% by weight of mica flakes or pellets, about 0.1 % to about 35% by weight of mica flakes or pellets, about 0.1 % to about 30% by weight of mica flakes or pellets, about 0.1 % to about 25% by weight of mica flakes or pellets, about 0.1% to about 20% by weight of mica flakes or pellets, about 0.1 % to about 15% by weight of mica flakes or pellets; about 0.1 % to about 10% by weight of mica flakes or pellets; about 0.1 % to about 5% by weight of mica flakes or pellets, about 0.1 % to about 2% by weight of mica flakes or pellets or any combinations thereof.

[0017] In some embodiments, material 10 includes a yarn comprising 100% cooling nylon. In some embodiments, material 10 includes a yarn comprising 100% cooling rayon. In some embodiments, material 10 includes a yarn comprising 100% cooling polyester.

[0018] It is envisioned that the yarns that make up material 10 may be of different sizes and/or may comprise different numbers of filaments. For example, material 10 may include a yarn comprising denier from about 1 D to about 200D and/or may include between about 10 and 200 filaments. In some embodiments, material 10 may include a yarn comprising 75D/72F wicking polyester (75 Denier with 72 filaments) Wicking polyester is designed to pull sweat and moisture away from skin toward the outside of fabric in order to evaporate quicker. Synthetics like polyester are hydrophobic, meaning the fabric doesn’t like moisture or sweat. Wicking polyester has a special cross-section and a large surface area, which picks up moisture and carries it away from your body, spreading it out, to evaporate easily on the outside of the fabric. They also have a capillary action that moves moisture from areas of high concentration to low concentration. Once the moisture reaches the outside of the fabric, it evaporates, or moves on to the next layer to start the process anew. So, you stay cool and dry. In some embodiments, material 10 may include a yarn comprising 40D/34F cooling nylon (40 Denier with 34 filaments). In some embodiments, material 10 may include a yarn o comprising 85% polyester and 35% nylon wherein material 10 comprises 75D/72F wicking polyester (75 Denier with 72 filaments) and 4QD/34F cooling nylon (40 Denier with 34 filaments). In some embodiments, material 10 may include a yarn comprising 70D/88F cooling nylon (70 Denier with 68 filaments). In some embodiments, material 10 may include a yarn comprising 52% polyester and 48% nylon wherein material 10 comprises 75D/72F wicking polyester (75 Denier with 72 filaments) and 70D/68F cooling nylon (70 Denier with 68 filaments). In some embodiments, material 10 may include a yarn comprising two plies of 4GD/34F cooling nylon (40 Denier with 34 filaments).

[0019] A plied yarn is one where multiple strands of yarn— already spun yarn— are put together and twisted in the opposite direction from that in which they were first twisted. This gives the yarn much more strength, durability and consistency than is seen in a singles yarn. A 2-ply yarn has two strands; a 3-ply yarn has three strands etc. You can have a very bulky two-ply yarn or an extremely thin four-ply yarn depending on how the individual singles were produced. In some embodiments, material 10 may include a yarn comprising 48% polyester and 52% nylon wherein material 10 comprises 75D/72F wicking polyester (75 Denier with 72 filaments) and two plies of 40D/34F cooling nylon (40 Denier with 34 filaments). In some embodiments, material 10 may include a yarn comprising 75D/72F cooling polyester (75 Denier with 72 filaments). In some embodiments, material 10 may include a yarn comprising 52% polyester and 48% nylon wherein material 10 comprises 75D/72F cooling polyester (75 Denier with 72 filaments) and 7GD/68F cooling nylon (70 Denier with 68 filaments).

[0020] In some embodiments, material 10 may include a yarn comprising 14SD/14QF cooling polyester. In some embodiments, material 10 may include a yarn comprising 52% polyester and 48% nylon wherein material 10 comprises 145D/140F cooling polyester (145 Denier with 140 filaments) and nylon blended. Nylon blended means a nylon yarn which is twisted together with other fibers e.g. polyester to make a blended yarn having beneficial properties. In some embodiments, material 10 may include a yarn comprising 26% polyester and 74% nylon wherein material 10 comprises 145D/14QF cooling polyester (145 Denier with 140 filaments), nylon and 140D/136F cooling nylon (140 Denier with 136 filaments). This is done just to achieve different levels of cooling. If we don’t want fabric to be 100% cooling then we can blend it with non-cooling yarns. In some embodiments, material 10 may include a yarn comprising 24% polyester and 76% nylon wherein material 10 comprises 145D/14QF cooling polyester (145 Denier with 140 filaments), nylon and 150D/144F cooling nylon (150 Denier with 144 filaments). In some embodiments, material 10 may include a yarn comprising 52% rayon and 48% nylon wherein material 10 comprises 75D/72F cooling rayon (75 Denier with 72 filaments) and 70 D/68 F cooling nylon (70 Denier with 68 filaments). In some embodiments, material 10 may include a yarn comprising 52% rayon and 48% nylon wherein material 10 comprises 145D/140F cooling rayon (145 Denier with 140 filaments) and nylon blended.

[0021] In some embodiments, material 10 may include a yarn comprising 26% rayon and 74% nylon wherein material 10 comprises 145D/140F cooling rayon (145 Denier with 140 filaments), nylon blended and 14QD/136F cooling nylon (140 Denier with 136 filaments). In some embodiments, material 10 may include a yarn comprising 24% rayon and 76% nylon wherein material 10 comprises 145D/14GF cooling rayon (145 Denier with 140 filaments), nylon blended and 150D/144F cooling nylon (150 Denier with 144 filaments). In some embodiments, material 10 may include a yarn comprising 50% rayon and 50% polyester wherein material 10 comprises 75 D/72 F cooling rayon (75 Denier with 72 filaments) and 75D/72F cooling polyester (75 Denier with 72 filaments). In some embodiments, material 10 may include a yarn comprising 50% rayon and 50% polyester wherein material 10 comprises 150D/144F cooling rayon (150 Denier with 144 filaments) and polyester blended.

[0022] In some embodiments, material 10 may include a yarn comprising 50% rayon and 50% polyester wherein material 10 comprises 150D/144F cooling rayon (150 Denier with 144 filaments) and polyester blended. In some embodiments, material 10 may include a yarn comprising 25% rayon and 75% polyester wherein material 10 comprises 150D/144F cooling rayon (150 Denier with 144 filaments), polyester blended and 15GD/144F cooling polyester (150 Denier with 144 filaments). In some embodiments, material 10 may include a type of polyester blended yarn where cooling polyester filaments are twisted together with regular filaments to form a poly blended yarn. This is done just to achieve different levels of cooling. In some embodiments, material 10 may include a type of polyester blended yarn without non- cooling yarns. In some embodiments, material 10 may include a yarn comprising 75% rayon and 25% polyester wherein material 10 comprises 15GD/144F cooling rayon (150 Denier with 144 filaments), polyester blended and 15GD/144F cooling polyester (150 Denier with 144 filaments). In some embodiments, material 10 may include a yarn comprising 100% 140D/136F cooling nylon (140 Denier with 136 filaments) in some embodiments, material 10 may include a yarn comprising 100% 150D/144F cooling rayon (150 Denier with 144 filaments). In some embodiments, material 10 may include a yarn comprising 100% 15GD/144F cooling polyester (150 Denier with 144 filaments).

[0023] It is envisioned that the yarns that make up material 10 may have different densities. For example, material 10 may have an average density between about 0.1 % and about 5.0%. In some embodiments, material 10 has an average density between about 0.5% and about 1.6%. In some embodiments, material 10 has an average density of 1.1 %.

[0024] It is envisioned that the yarns that make up material 10 may have different boil-off shrinkages. For example, material 10 may have a boil-off shrinkage between about 1.0% and about 15.0%. In some embodiments, material 10 has a boil- off shrinkage between about 4.0% and about 12.0%. In some embodiments, material 10 has a boil-off shrinkage of 8.1 %.

[0025] It is envisioned that the yarns that make up material 10 may have different break elongations. For example, material 10 may have a break elongation between about 5.0% and about 20.0% In some embodiments, material 10 has a break elongation between about 12.0% and about 16.0%. In some embodiments, material 10 has a break elongation of 14 4%.

[0026] It is envisioned that the yarns that make up material 10 may have different tenacities. For example, material 10 may have a tenacity between about 0.1 CN/D and about 10.0 CN/D. In some embodiments, material 10 has a tenacity between about 3.0 CN/D and about 7.0 CN/D. In some embodiments, material 10 has a tenacity of 5.51 CN/D [0027] In some embodiments, the yarns that make up material 10 may are knitted to form material 10. For example, material 10 may be formed using a weft knitting method, such as, for example, a circular knitting technique. The yarns are run in wales and courses wherein the wales are perpendicular to the course of the yarn. In some embodiments, material 10 has about 20 to about 60 wales per inch and about 35 to about 75 courses per inch. In some embodiments, material 10 has about 30 to about 50 wales per inch and about 45 to about 65 courses per inch. In some embodiments, material 10 has 40 wales per inch and 55 courses per inch.

[0028] Material 10 comprises a top surface 12 and an opposite bottom surface 14 A central portion 16 is positioned between surfaces 12, 14 Surface 12 comprises a fiber 18, surface comprises a fiber 20, and portion 16 comprises fibers 18, 20 and a fiber 22. At least one of fibers 18, 20 includes a material, such as, for example, one or more of the cooling materials discussed herein. In some embodiments, at least one of fibers 18, 20 includes nylon, rayon and/or polyester. In some embodiments, at least one of fibers 18, 20 includes cooling nylon, cooling rayon and/or cooling polyester. Fiber 22 is configured to maintain fibers 18, 20 such that a user’s skin will only contact fiber 18 and/or fiber 20 when the user touches material 10. That is, the users skin will not directly contact fiber 22 when the user touches material 10.

[0029] In some embodiments, fiber 18 and/or fiber 20 may comprise a material, such as, for example, rayon, nylon and/or polyester that is cool to the touch such that when the user touches material 10 fiber 18 and/or fiber 20 will provide a cooling effect. In some embodiments, fiber 18 and/or fiber 20 may comprise a material, such as, for example, cooling rayon, cooling nylon and/or cooling polyester that is cool to the touch such that when the user touches material 10 fiber 18 and/or fiber 20 will provide a cooling effect. In some embodiments, fiber 22 is the same as at least one of fibers 18, 20. For example, fiber 22 may be made from the same or similar materials as at least one of fibers 18, 20. In some embodiments, fiber 22 is different than at least one of fibers 18, 20. For example, fiber 22 may be made from different materials than at least one of fibers 18, 20. As discussed herein, forming at least one of fibers 18, 20 from a cooling material, such as, for example, one or more of the cooling materials discussed herein, provides a cooling effect when touched. As such, while at least one of fibers 18, 20 is made from a material that provides a cooling effect, fiber 22 is not required to be made from a material that provides a cooling effect. Therefore, in some embodiments, fiber 22 is made from a material that provides a cooling effect and in other embodiments, fiber 22 is not made from a material that provides a cooling effect.

[0030] As shown in FIGS. 1 and 2, material 10 is made by forming fiber 20 to have a plurality of loops, such as, for example, loops 20a, 20b, 20c and forming fiber 22 to have a plurality of loops, such as, for example, loops 22a, 22b, 22c. Fiber 20 includes a loop 20d that is positioned between loops 20a, 20b and a loop 20e that is positioned between loops 20b, 20c. Loops 20d, 20e are positioned opposite of loops 20a, 20b, 20c. Fiber 22 includes a loop 22d that is positioned between loops 22a, 22b and a loop 22e that is positioned between loops 22b, 22c. Loops 22d, 22e are positioned opposite of loops 22a, 22b, 22c. Loop 22a is positioned through loop 20a using a circular knitting technique such that loop 22a is aligned with loop 20a. Loop 22b is positioned through loop 20b using a circular knitting technique such that loop 22b is aligned with loop 20b. Loop 22c is positioned through loop 20c using a circular knitting technique such that loop 22c is aligned with loop 20c. Loop 2Gd is positioned through loop 22d using a circular knitting technique such that loop 22d is aligned with loop 20d. Loop 20e is positioned through loop 22e using a circular knitting technique such that loop 22e is aligned with loop 2Ge.

[0031] Fiber 18 is formed to have a plurality of loops, such as, for example, loops 18a, 18b, 18c. Fiber 18 includes a loop 18d that is positioned between loops 18a, 18b and a loop 18e that is positioned between loops 18b, 18c. Loops 18d, 18e are positioned opposite of loops 18a, 18b, 18c. Loop 18a is positioned through loop 22a using a circular knitting technique such that loop 18a is aligned with loop 20a and loop 22a. Loop 18b is positioned through loop 22b using a circular knitting technique such that loop 18b is aligned with loop 20b and loop 22b. Loop 18c is positioned through loop 22c using a circular knitting technique such that loop 18c is aligned with loop 20c and loop 22c. Loop 22d is positioned through loop 18d using a circular knitting technique such that loop 22d is aligned with loop 18d and loop 20d. Loop 22e is positioned through loop 18e using a circular knitting technique such that loop 22e is aligned with loop 18e and loop 20e. This configuration allows loops 18a, 18b, 18c to form top surface 12 of material 10 and loops 20d, 20e to form bottom surface 14 of material 10, as shown in FIGS. 1 and 2.

[0032] At least one of fibers 18, 20 includes a material, such as, for example, one or more of the cooling materials discussed herein. In some embodiments, at least one of fibers 18, 20 includes nylon, rayon and/or polyester. In some embodiments, at least one of fibers 18, 20 includes cooling nylon, cooling rayon and/or cooling polyester. In some embodiments, at least one of fibers 18, 20 includes nylon, rayon, polyester, cooling nylon, cooling rayon and/or cooling polyester. In some embodiments, at least one of fibers 18, 20 includes cooling nylon and/or cooling rayon. In some embodiments, at least one of fibers 18, 20 includes cooling polyester and/or cooling rayon. In some embodiments, at least one of fibers 18, 20 includes cooling nylon and/or cooling polyester. In some embodiments, fiber 18 includes cooling nylon and fiber 20 includes cooling rayon. In some embodiments, fiber 18 includes cooling rayon and fiber 20 includes cooling nylon. In some embodiments, fiber 18 includes cooling polyester and fiber 20 includes cooling rayon. In some embodiments, fiber 18 includes cooling rayon and fiber 20 includes cooling polyester. In some embodiments, fiber 18 includes cooling nylon and fiber 20 includes cooling polyester. In some embodiments, fiber 18 includes cooling polyester and fiber 20 includes cooling nylon.

[0033] In some embodiments, fiber 18 and/or fiber 20 include(s) a blend of materials such that fiber 18 and/or fiber is/are a blended yarn. For example, in some embodiments, fiber 18 and/or fiber 20 may comprise 65% polyester and 35% nylon wherein fiber 18 and/or fiber 20 comprises 75D/72F wicking polyester [75 Denier with 72 filaments) and 40D/34F cooling nylon (40 Denier with 34 filaments). In some embodiments, fiber 18 and/or fiber 20 may comprise 52% polyester and 48% nylon wherein fiber 18 and/or fiber 20 comprises 75D/72F wicking polyester (75 Denier with 72 filaments) and 70D/68F cooling nylon (70 Denier with 68 filaments). In some embodiments, fiber 18 and/or fiber 20 may include two plies of 40D/34F cooling nylon (40 Denier with 34 filaments). In some embodiments, fiber 18 and/or fiber 20 comprises 48% polyester and 52% nylon wherein fiber 18 and/or fiber 20 comprises 75D/72F wicking polyester (75 Denier with 72 filaments) and two plies of 40D/34F cooling nylon (40 Denier with 34 filaments). In some embodiments, fiber 18 and/or fiber 20 comprises 75D/72F cooling polyester (75 Denier with 72 filaments). In some embodiments, fiber 18 and/or fiber 20 comprises 52% polyester and 48% nylon wherein fiber 18 and/or fiber 20 comprises 75D/72F cooling polyester (75 Denier with 72 filaments) and 70D/68F cooling nylon (70 Denier with 68 filaments).

[0034] In some embodiments, fiber 18 and/or fiber 20 comprises 145D/14QF cooling polyester (145 Denier with 140 filaments). In some embodiments, fiber 18 and/or fiber 20 comprises 52% polyester and 48% nylon wherein fiber 18 and/or fiber 20 comprises 145D/140F cooling polyester (145 Denier with 140 filaments) and nylon blended. In some embodiments, fiber 18 and/or fiber 20 comprises 26% polyester and 74% nylon wherein fiber 18 and/or fiber 20 comprises 145D/140F cooling polyester (145 Denier with 140 filaments), nylon and 140D/136F cooling nylon (140 Denier with 136 filaments). In some embodiments, fiber 18 and/or fiber 20 comprises 24% polyester and 76% nylon wherein fiber 18 and/or fiber 20 comprises 145D/14QF cooling polyester (145 Denier with 140 filaments), nylon and 150D/144F cooling nylon (150 Denier with 144 filaments). In some embodiments, fiber 18 and/or fiber 20 comprises 52% rayon and 48% nylon wherein fiber 18 and/or fiber 20 comprises 75D/72F cooling rayon (75 Denier with 72 filaments) and 70D/68F cooling nylon (70 Denier with 68 filaments). In some embodiments, fiber 18 and/or fiber 20 comprises 52% rayon and 48% nylon wherein fiber 18 and/or fiber 20 comprises 145D/14GF cooling rayon (145 Denier with 140 filaments) and nylon blended.

[0035] In some embodiments, fiber 18 and/or fiber 20 comprises 26% rayon and 74% nylon wherein fiber 18 and/or fiber 20 comprises 145D/140F cooling rayon (145 Denier with 140 filaments), nylon blended and 140D/136F cooling nylon (140 Denier with 136 filaments). In some embodiments, fiber 18 and/or fiber 20 comprises 24% rayon and 76% nylon wherein fiber 18 and/or fiber 20 comprises 145D/140F cooling rayon (145 Denier with 140 filaments), nylon blended and 150D/144F cooling nylon (150 Denier with 144 filaments). In some embodiments, fiber 18 and/or fiber 20 comprises 50% rayon and 50% polyester wherein fiber 18 and/or fiber 20 comprises 75D/72F cooling rayon (75 Denier with 72 filaments) and 75D/72F cooling polyester (75 Denier with 72 filaments). In some embodiments, fiber 18 and/or fiber 20 comprises 50% rayon and 50% polyester wherein fiber 18 and/or fiber 20 comprises 150D/144F cooling rayon (150 Denier with 144 filaments) and polyester blended.

[0036] In some embodiments, fiber 18 and/or fiber 20 comprises 50% rayon and 50% polyester wherein fiber 18 and/or fiber 20 comprises 150D/144F cooling rayon (150 Denier with 144 filaments) and polyester blended. In some embodiments, fiber 18 and/or fiber 20 comprises 25% rayon and 75% polyester wherein fiber 18 and/or fiber 20 comprises 15GD/144F cooling rayon (150 Denier with 144 filaments), polyester blended and 150D/144F cooling polyester (150 Denier with 144 filaments). In some embodiments, fiber 18 and/or fiber 20 comprises 75% rayon and 25% polyester wherein fiber 18 and/or fiber 20 comprises 15QD/144F cooling rayon (150 Denier with 144 filaments), polyester blended and 150D/144F cooling polyester (150 Denier with 144 filaments). In some embodiments, fiber 18 and/or fiber 20 comprises 100% 140D/136F cooling nylon (140 Denier with 136 filaments). In some embodiments, fiber 18 and/or fiber 20 comprises 100% 150D/144F cooling rayon (150 Denier with 144 filaments). In some embodiments, fiber 18 and/or fiber 20 comprises 100% 150D/144F cooling polyester (150 Denier with 144 filaments).

EXAMPLE 1

[0637] The maximum level of the contact heat flow q-max (W/cm²) of various yams was determined to assess the suitability of such yarns for use in cooling materials, such as, for example, cooling material 10. The q-max for each yarn was determined by measuring the peak value of heat current immediately after the heat stored on a pure copper plate (area: 9cm², weight: 9.79g) travels to a specimen when the plate touches the surface of the specimen. The q-max for each yarn tested is shown in FIG. 3. As shown in FIG. 5, a range of yarns were looked at in order to decide which yam will be most suitable for as a suitable cooling fabric. Yarns were shortlisted based of their Qmax properties and melange effect.

[0638] While it was expected that yarns that include blends of only cooling nylon, cooling rayon and/or cooling polyester would have higher q-max scores than yarns that include blends of cooling nylon, cooling rayon and/or cooling polyester and nylon, rayon and/or polyester, as shown in FIG. 3, the yarn that included cooling rayon and nylon had a higher q-max score than the yarn that included cooling rayon and cooling nylon (0.359/0.301 and 0.33/0.29).

EXAMPLE 2

[0039] The melange effect of various yarns was determined to assess the suitability of such yarns for use in cooling materials, such as, for example, cooling material 10. In some examples, the melange effect is a color effect achieved by cross dyeing fabric made from more than one type of fiber. The process involving dipping the fabric into several different dye baths specifically chosen for their affinity to the fibers so that each fiber type will only absorb certain dyes. In order to create melange yarn, the fiber is usually dyed before spinning. The melange effect for each yam tested is shown in FIG. 4. As shown in FIG. 4, yarns that include blends of only cooling nylon, cooling rayon and/or cooling polyester have an uneven melange effect and yarns that include blends of cooling nylon, cooling rayon and/or cooling polyester and nylon, rayon and/or polyester have an even melange effect. In that yarns that include blends of cooling nylon, cooling rayon and/or cooling polyester and nylon, rayon and/or polyester have an even melange effect and have q-max scores that are higher than yarns that include blends of only cooling nylon, cooling rayon and/or cooling polyester (and have an uneven melange effect), it may be preferable to use yarns that include blends of cooling nylon, cooling rayon and/or cooling polyester and nylon, rayon and/or polyester over yarns that include blends of only cooling nylon, cooling rayon and/or cooling polyester for use in a cooling material, such as, for example, cooling material 10, since such yarns have been shown to demonstrate superior q-max scores and melange effects.

[0040] It will be understood that various modifications may be made to the embodiments disclosed herein. For example, features of any one embodiment can be combined with features of any other embodiment. Therefore, the above description should not be construed as limiting, but merely as exemplification of the various embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.

Claims

WHAT IS CLAIMED IS:

1. A cooling materia! comprising opposite top and bottom surfaces and a centra! portion positioned between the top and bottom surfaces, the top surface comprising a first fiber, the bottom surface comprising a second fiber, the middle portion comprising the first and second fibers and a third fiber.

2. A cooling materia! as recited in claim 1 , wherein the first and second fibers are nylon fibers and the third fiber is a rayon fiber.

3. A cooling materia! as recited in claim 1 , wherein the first and second fibers comprise 52% rayon by weight and 48% nylon by weight.

4. A cooling materia! as recited in claim 1 , wherein the first and second fibers are uncrimped nylon fibers and the third fiber is an uncrimped rayon fiber.

5. A cooling materia! as recited in claim 1 , wherein the first and second fibers are nylon filaments and the third fiber is a rayon filament.

6. A cooling materia! as recited in claim 1 , wherein the first and second fibers are nylon fibers and the third fiber is a polyester fiber.

7. A cooling materia! as recited in claim 1 , wherein the first and second fibers are uncrimped nylon fibers and the third fiber is an uncrimped polyester fiber

8. A cooling material as recited in claim 1 , wherein the first and second fibers are nylon filaments and the third fiber is a polyester filament.

9. A cooling materia! as recited in claim 1 , wherein the first fiber is spaced apart from the second fiber by the third fiber.

10. A cooling materia! as recited in claim 1 , wherein the top surface comprises spaced apart loops of the first fiber and the bottom surface comprises spaced apart loops of the second fiber.

1 1. A cooling materia! as recited in claim 1 , wherein the middle portion comprises spaced apart first loops of the second fiber and spaced apart second loops of the second fiber, the first fiber being positioned in the first loops and the second fiber being positioned in the second loops.

12. A cooling material as recited in claim 1 , wherein the middle portion comprises spaced apart first loops of the second fiber and spaced apart second loops of the second fiber, the first fiber comprising loops that are positioned in the first loops and the second fiber comprising loops that are positioned in the second loops.

13. A cooling materia! as recited in claim 12, wherein the loops of the first fiber are aligned with the first loops and the loops of the second fiber are aligned with the second loops.

14. A cooling materia! as recited in claim 1 , wherein the cooling materia! has an average density between about 0 1 % and about 2.0%.

15. A cooling materia! as recited in claim 1 , wherein the cooling materia! has an average density of 1.1 %.

16. A cooling materia! as recited in claim 1 , wherein the cooling materia! has a boil-off shrinkage between about 5.0% and about 10.0%.

17. A cooling materia! as recited in claim 1 , wherein the cooling materia! has a boil-off shrinkage of 8.1 %.

18. A blended yam as recited in claim 1 , wherein the cooling material has a break elongation between about 10.0% and about 20.0%.

19. A cooling materia! as recited in claim 1 , wherein the cooling materia! has a break elongation of 14.4%.

20. A cooling material as recited in claim 1 , wherein the cooling materia! has a tenacity between about 3.0 CN/D and about 8.0 CN/D.

21. A cooling materia! as recited in claim 1 , wherein the cooling material has a tenacity of 5.51 CN/D.

22. A cooling materia! as recited in claim 1 , wherein the cooling materia! comprises between about 20 and about 60 wales per inch and between about 35 and about 75 courses per inch.

23. A cooling materia! as recited in claim 1 , wherein the cooling material comprises 40 wales per inch and 55 courses per inch.

24. A cooling materia! comprising opposite top and bottom surfaces and a centra! portion positioned between the top and bottom surfaces, the top surface consisting of a first fiber, the bottom surface consisting of a second fiber, the middle portion consisting of the first and second fibers and a third fiber.

25 A cooling materia! as recited in claim 24, wherein the first and second fibers are nylon fibers and the third fiber is a rayon fiber.

26. A cooling materia! as recited in claim 24, wherein the first and second fibers are nylon fibers and the third fiber is a rayon fiber, the first and second fibers comprising 48% of the blended yarn by weight and the third fiber comprising 52% of the blended yarn by weight.

27. A cooling materia! as recited in claim 24, wherein the first and second fibers are uncrimped nylon fibers and the third fiber is an uncrimped rayon fiber.

28 A cooling materia! as recited in claim 24, wherein the first and second fibers are nylon filaments and the third fiber is a rayon filament.

29. A cooling materia! as recited in claim 24, wherein the first and second fibers are nylon fibers and the third fiber is a polyester fiber.

30. A cooling materia! as recited in claim 24, wherein the first and second fibers are uncrimped nylon fibers and the third fiber is an unch ped polyester fiber.

31 A cooling materia! as recited in claim 24, wherein the first and second fibers are nylon filaments and the third fiber is a polyester filament.

32. A cooling materia! as recited in claim 24, wherein the first fiber is spaced apart from the second fiber by the third fiber.

33. A cooling material comprising opposite top and bottom surfaces and a centra! portion positioned between the top and bottom surfaces, the top surface comprising a first fiber, the bottom surface comprising a second fiber, the middle portion comprising the first and second fibers and a third fiber, wherein at least one of the first and second fibers comprises a nylon fiber and the third fiber is a rayon fiber, the nylon fiber comprising flakes of mica and flakes of nylon that are melted together and extruded to form the nylon fiber.