WO2019173583A1 - Matériaux composites et procédés de fabrication - Google Patents

Matériaux composites et procédés de fabrication Download PDF

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Publication number
WO2019173583A1
WO2019173583A1 PCT/US2019/021141 US2019021141W WO2019173583A1 WO 2019173583 A1 WO2019173583 A1 WO 2019173583A1 US 2019021141 W US2019021141 W US 2019021141W WO 2019173583 A1 WO2019173583 A1 WO 2019173583A1
Authority
WO
WIPO (PCT)
Prior art keywords
spacer
fabric
spacer material
yarn
composite material
Prior art date
Application number
PCT/US2019/021141
Other languages
English (en)
Inventor
Kirk Michael MAYER
Austin Dean STOUT
Original Assignee
The North Face Apparel Corp.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by The North Face Apparel Corp. filed Critical The North Face Apparel Corp.
Publication of WO2019173583A1 publication Critical patent/WO2019173583A1/fr

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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B21/02—Pile fabrics or articles having similar surface features
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B21/10—Open-work fabrics
    • D04B21/12—Open-work fabrics characterised by thread material
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2403/00—Details of fabric structure established in the fabric forming process
    • D10B2403/01—Surface features
    • D10B2403/011—Dissimilar front and back faces
    • D10B2403/0111—One hairy surface, e.g. napped or raised
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2403/00—Details of fabric structure established in the fabric forming process
    • D10B2403/01—Surface features
    • D10B2403/011—Dissimilar front and back faces
    • D10B2403/0112—One smooth surface, e.g. laminated or coated
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2403/00—Details of fabric structure established in the fabric forming process
    • D10B2403/02—Cross-sectional features
    • D10B2403/021—Lofty fabric with equidistantly spaced front and back plies, e.g. spacer fabrics
    • D10B2403/0213—Lofty fabric with equidistantly spaced front and back plies, e.g. spacer fabrics with apertures, e.g. with one or more mesh fabric plies
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2403/00—Details of fabric structure established in the fabric forming process
    • D10B2403/02—Cross-sectional features
    • D10B2403/022—Lofty fabric with variably spaced front and back plies, e.g. spacer fabrics
    • D10B2403/0223—Lofty fabric with variably spaced front and back plies, e.g. spacer fabrics with apertures, e.g. with one or more mesh fabric plies

Definitions

  • a spacer material may comprise discrete pieces of plain knit or jacquard fabric joined by a yarn, such as a tie yam.
  • the yarn may define a spacer region.
  • the spacer region may be a breathable, three-dimensional microclimate between the pieces of fabric.
  • the pieces of fabric may be formed independently of each other and of the tie yam.
  • the spacer material may be manufactured by bonding a discrete piece of fabric and the tie yarn.
  • the spacer material may be heavy. The spacer material may cause discomfort to a user when the spacer material is in contact with a body of the user. Thus, improvements in spacer materials are needed.
  • a composite material may comprise a fabric spacer and one or more portions.
  • the fabric spacer may comprise a yarn structure.
  • the portion which may comprise a terry loop fabric and/or a warp knit fabric, may be coupled to a surface of the fabric spacer by the yam structure. If the composite material comprises more than one portion, the portions may be coupled to different surfaces of the fabric spacer by the yam structure.
  • the composite material may be manufactured by warp knitting the fabric spacer and the first portion. At least a portion of the fabric spacer and at least a portion of the first portion may be knit contemporaneously, such as using a Raschel warp knitting machine.
  • the composite material may be manufactured by warp knitting more than portions and tying the portions to the fabric spacer with the yarn, simultaneously.
  • the contemporaneous warp knitting of the fabric spacer and the first portion may result in a composite material with increased thermal properties compared to a composite material formed by bonding or adhesion of the fabric spacer and the first portion.
  • FIG. 1 shows an example spacer material.
  • FIG. 2 shows an example spacer material.
  • FIG. 3 shows an example spacer material.
  • FIG. 4 shows an example spacer material.
  • FIG. 5 shows an example spacer material.
  • FIG. 6 shows an example spacer material.
  • FIG. 7 shows an example spacer material.
  • FIG. 8 shows an example spacer material.
  • FIG. 9 shows an example spacer material.
  • FIG. 10 shows an example spacer material.
  • FIG. 11 shows an example spacer material.
  • FIG. 1 shows an example spacer material 100.
  • the spacer material 100 may comprise a spacer structure 101 and one or more fabric layers or portions 102.
  • the spacer material 100 may be cushioned.
  • the spacer material 100 may be air permeable.
  • the spacer material 100 may comprise a three-dimensional material.
  • the spacer material 100 may be configured to may retain heat in a spacer region 103 of the spacer material 100 where the spacer structure 101 is disposed.
  • the spacer material 100 may be configured to absorb heat from an environment external to the spacer material 100.
  • the spacer material 100 may be configured to retain heat within the spacer region 103, such as to insulate a user of an article comprising the spacer material 101.
  • the spacer region 103 may comprise a microclimate.
  • the spacer region 103 may be highly permeable to air.
  • the spacer region 103 may comprise an air permeable “microclimate.”
  • the spacer region 103 may comprise a thermoregulator, configured to trap heat in the voids in the spacer structure 101 before releasing the heat, such as out a side of the spacer material 100 that is not in contact with the body of the user or into the environment external to the spacer material 100.
  • the heat trapped in the spacer region 103 may be expelled by cool air that permeates through the spacer region 103.
  • the spacer material 100 may be configured to wick moisture from a body to the spacer region 103. As an illustrative example, if a person is wearing apparel comprising the spacer material 100, the spacer material 100 may absorb sweat from the skin of the user. The wicking of moisture may cause a drying effect for a user of an article comprising the spacer material 100. The moisture may be retained within the spacer region 103. The spacer material 100 may be configured to release the moisture, such as out a side of the spacer material 100 that is not in contact with the body of the user or into the environment external to the spacer material 100. The moisture may be expelled from the spacer region 103 by cool air that permeates through the spacer region 103. The spacer material 100 may be configured to repel water or moisture. For example, the spacer material 100 may be chemically treated, such as with a durable water repellant (DWR), to repel water or moisture.
  • DWR durable water repellant
  • FIG. 2 shows an example spacer material 200.
  • the spacer material 200 may be similar to the spacer material 100 in FIG. 1.
  • the spacer material 200 may have a gauge of 20-25, 25-30, or 30-35, as examples.
  • the spacer material 200 may comprise a spacer structure 201.
  • the spacer structure 201 may comprise a warp knit fabric.
  • the spacer structure 201 may comprise a yam.
  • yarn include polyester yarn, polyester and elastane/spandex blend yarn, nylon yam, acrylic yarn, or another synthetic yarn.
  • Additional examples of yam include spun yarns, such as spun cotton yarn, spun wool yarn, or spun synthetic yam.
  • the yam may have a thickness of 1-12 millimeters, as an example.
  • the yarn may comprise a type of yarn selected based on desired properties of the spacer material 200 or of an article comprising the spacer material 200.
  • the type of yarn may be selected based on a property of the type of yam.
  • properties of yarns include thickness, weight, warp roughness or glide, loop height, air permeability, insulation (e.g., CLO value), and flex rigidity.
  • the yarn may comprise a fiber with a density selected for water resistance or moisture wicking properties.
  • the yam may comprise a microfiber with a denier per filament (“DPF”) of less than or equal to 300. A microfiber with a DPF of less than or equal to one may be selected to make the spacer material 200 configured for moisture
  • the yarn may comprise a macrofiber with a DPF of greater than or equal to one.
  • a macrofiber with a DPF of greater than or equal to one may be selected to make the spacer material 200 configured for resistance to abrasion and physical stresses. For example, resistance to abrasion and physical stresses may be desirable in a spacer material 200 to be used to make footwear.
  • the yarn may comprise a monofilament yam, such as a monofilament loft yarn.
  • the yam may comprise a multifilament yam, such as a multifilament tie yarn.
  • the yam may be chemically treated.
  • the yarn may be mechanically finished.
  • the spacer structure 201 may comprise a substantially rigid spacer material.
  • a substantially rigid material may be defined as a material with a bending angle between 0 degrees and 20 degrees on a cantilever fabric stiffness test, such as the ASTM D1388 standard test.
  • the spacer structure 201 may comprise a blend of a substantially rigid material and a stretchable material.
  • the spacer structure 201 may comprise 90% or more substantially rigid material and 10% or less stretchable material.
  • the spacer structure 201 may comprise 80% or more substantially rigid material and 20% or less stretchable material.
  • the stretchable material may comprise a 2-way stretchable material, such as mesh.
  • the stretchable material may comprise a 4-way stretchable material, such as elastane or spandex.
  • the stretchable material may comprise a material that has been mechanically stretched.
  • the spacer structure 201 may comprise a blend of monofilament yarns and multifilament yarns. As an illustrative example, the spacer structure 201 may comprise 90% or more substantially rigid material and 10% or less stretchable material. As another illustrative example, the spacer structure 201 may comprise 80% or more substantially rigid material and 20% or less stretchable material.
  • the spacer structure 201 may comprise a three-dimensional structure.
  • the three-dimensional structure may comprise, for example, a sawtooth structure, a triangular structure, a rectangular structure, a curved structure, a crosshatch structure, a grated structure, or a wave structure.
  • the shape of the structure may be defined by the arrangement of filaments. For example, for a triangular structure, filaments may be arranged to form triangular shapes.
  • the spacer structure 201 may have a uniform thickness throughout the spacer material.
  • the thickness may be defined by a distance between a first side 204 of the spacer structure 201 and a second side 205 of the spacer structure 201.
  • the spacer structure 201 may have a variable thickness throughout the spacer material 202.
  • the spacer structure 201 may have a thickness of 1-11 mm, 2-12 mm, or 3-13 mm, as examples.
  • the spacer structure 201 may comprise channels, folds, or bend lines.
  • the channels, folds, or bend lines may comprise a Jacquard design.
  • the spacer structure may comprise a pattern.
  • the pattern may define the channels, folds, or bend lines.
  • the channels, folds, or bend lines may be configured to enable packing of the spacer material 200, such as for packing or transport of the spacer material 200.
  • the channels, folds, or bend lines may be configured to enable draping of the spacer material 200. Draping may comprise flexing or cascading over a body, such as without producing tight spots or rigidity.
  • the spacer structure may comprise a natural bend line, such as a flex, hinge, or taper, which may enhance fit or ease of movement.
  • Spacer material 200 may comprise a fabric layer or portion 202.
  • the fabric portion 202 may comprise a type of fabric selected based on desired properties of the spacer material 200 or of an article comprising the spacer material 200.
  • the fabric portion 202 may comprise a warp knit fabric.
  • the fabric portion 202 may comprise a multifilament yarn or a monofilament yarn.
  • the fabric portion 202 may be mechanically napped, such as to create a lofty surface.
  • the fleece may cause further heat absorption or retention by the spacer material.
  • the fleece may comprise a grid structure.
  • the grid structure may comprise fleece that has been sheared, brushed, or napped.
  • the grid structure may be configured to minimize weight.
  • the grid structure may be enable folding of the spacer material 200, such as for packing.
  • the grid structure may be configured to maximize drying of the spacer material 200.
  • the fabric portion 202 may comprise a plurality of loops.
  • the loops may comprise open loops, such as sheared loops or brushed loops.
  • the loops may comprise closed loops, such as terry loops.
  • the loops may comprise a structure adapted to be worn against the body of a user without causing discomfort.
  • the loops may have a height of 1 mm or less, 1-1.5 mm, 1.5-2.5 mm, or another height, as examples.
  • the loops may be interlocked with at least a portion of the spacer structure 201.
  • the loops may retain heat or air.
  • the fabric portion 202 may comprise a mesh or a fabric with pores.
  • the fabric portion 202 may comprise a fabric configured to adhere to a surface or to another fabric, such as Velcro.
  • the fabric portion 202 may be disposed adjacent the spacer structure 201.
  • the fabric portion 202 may be configured to be in contact with the body of a user of an article comprising the spacer material 200 when the article is in normal use.
  • the fabric portion 202 may be configured to be exposed to the environment external to the spacer material 200, such as to cause insulation of heat within the spacer material 200.
  • the fabric portion 202 may be chemically treated.
  • the fabric portion 202 may be mechanically finished.
  • the spacer material 200 may be manufactured by knitting the spacer structure 201 and the fabric portion 202, contemporaneously.
  • the spacer structure 201 and the fabric portion 202 may be knit contemporaneously using a warp knitting machine.
  • the warp knitting machine may comprise a Raschel machine, as an example.
  • the warp knitting machine may comprise a machine manufactured by Karl Mayer or a similar machine.
  • knitting the spacer structure 201 and the fabric portion 202 may comprise knitting a plurality of loops of the fabric portion 202 interlocking at least a portion of the spacer structure 201.
  • the spacer material 200 comprises two or more fabric layers or portions 202, the fabric portions may be warp knit contemporaneously.
  • the spacer structure 201 may be knit by knitting one or more yarns joining the fabric portions 202.
  • the spacer structure 201 may tie the fabric portions 202.
  • the spacer structure 201 may be knit contemporaneous with the knitting of the fabric portions 202.
  • Knitting the spacer structure 201 and the fabric portion 202 contemporaneously may eliminate the need to bond the spacer structure 201 and the fabric portion 202 with an adhesive. Knitting the spacer structure 201 and the fabric portion 202 contemporaneously may produce a spacer material 200 that is lighter than a spacer material formed by bonding a spacer structure and a fabric structure.
  • the spacer material 200 may weight around 200 g/m 2 , 220 g/m 2 , 250 g/m 2 , 275 g/m 2 , 300 g/m 2 , 350 g/m 2 , 400 g/m 2 , 450 g/m 2 , 500 g/m 2 , or 550 g/m 2 .
  • Knitting the spacer structure 201 and the fabric portion 202 contemporaneously may produce a spacer material 200 that is thinner than a spacer material formed by bonding a spacer structure and a fabric structure. Knitting the spacer structure 201 and the fabric portion 202 contemporaneously may produce a spacer material 200 that has superior heat insulating properties than a spacer material formed by bonding a spacer and a fabric structure.
  • the spacer material 200 may be as drapable, stretchable, and conformable to a body of a user as a spacer material formed by bonding a spacer and a fabric structure.
  • Knitting the spacer structure 201 and the fabric portion 202 contemporaneously may produce a spacer material 200 that is more comfortable for a user of an article comprising the spacer material 200.
  • the fabric portion 202 may cover the spacer structure 201.
  • the fabric portion 202 may be knit to form a structure that is softer than the spacer structure 201.
  • the fabric portion 202 may comprise a raised terry loop surface.
  • the spacer structure 201 may comprise a tie yarn or a stiff, synthetic monofilament yarn.
  • the spacer structure 201 may comprise a high-loft spacer knit.
  • the fabric portion 202 may act as a barrier to the spacer structure 201. When in contact with a body of a user, the fabric portion 202 may prevent contact between the user’s body and the spacer structure 201, preventing potential discomfort caused by contact between the user’s body and the spacer structure.
  • the spacer material 200 may be used to manufacture a variety of articles of manufacture.
  • the spacer material 200 may be used to make apparel, such as clothing, bags, footwear, and accessories.
  • the spacer material 200 maybe used to make sporting equipment, such as tents, bags, and backpacks.
  • the spacer material 200 may be used for furniture or vehicle parts.
  • FIG. 3 shows an example spacer material 300 with two fabric portions 302.
  • the spacer material 300 may be similar to any of spacer material 100 in FIG. 1 or spacer material 200 in FIG. 2.
  • Each of the two fabric portions 302 may be disposed adjacent a side 304, 305 of the spacer material 300, such as on opposing sides of a spacer structure 301.
  • Each of the two fabric portions 302 may comprise a different fabric.
  • each of the two fabric portions 302 may comprise a different jacquard design.
  • FIG. 4 shows an example spacer material 400 with a first fabric portion 402a comprising a fleece with single- sided terry loops and a second fabric portion 402b comprising a lofty texture.
  • FIG. 5 shows an example spacer material 500 with a first fabric portion 502a comprising a fleece with single-sided terry loops and a second fabric portion 502c comprising a mesh.
  • a spacer material comprising two fabric portions may be reversible.
  • the spacer material may be configured to wick moisture from a body in contact with either of the two fabric portions.
  • the spacer material may be configured to release moisture via either of the two fabric portions, such as one of the two fabric portions that is not in contact with a body.
  • the spacer material may be configured to retain heat between the two fabric portions.
  • a spacer material comprising two fabric portions may be manufactured by knitting a spacer structure and the two fabric portions, contemporaneously.
  • Each of the two fabric portions may be knit on sides of the spacer structure, such as on opposing sides of the spacer structure.
  • the spacer structure and the fabric portions may be knit contemporaneously using a warp knitting machine.
  • the warp knitting machine may comprise a Raschel machine, as an example.
  • FIG. 6 shows an example spacer material 600 with a fabric portion 602 comprising a plurality of loops 606.
  • the spacer material 600 may be similar to any of spacer material 100 in FIG. 1, spacer material 200 in FIG. 2, spacer material 300 in FIG. 3, spacer material 400 in FIG. 4, or spacer material 500 in FIG. 5.
  • the spacer material 600 may comprise a spacer structure 601.
  • the loops 606 may not be distributed continuously across the fabric portion 602.
  • the loops 606 may be arranged in a pattern.
  • the loops 606 may be arranged in columns, clusters, squares, another discontinuous pattern, or randomly across the fabric portion 602. The pattern may be non-repeating.
  • the pattern may be selectively placed based on a shape or size of a body of a user.
  • the zones may be selectively placed based on a desired fabric property, such as a property desired for use on a particular part of a body of a user.
  • the arrangement of the loops 606 may be selected based on a desired property of the spacer material 600 or of an article comprising the spacer material 600.
  • the arrangement may define the channels, folds, or bend lines.
  • the channels, folds, or bend lines may be configured to enable packing of the spacer material 600, such as for packing or transport of the spacer material 600.
  • the channels, folds, or bend lines may be configured to enable draping of the spacer material 600. Draping may comprise flexing or cascading over a body, such as without producing tight spots or rigidity.
  • FIG. 7 shows an example spacer material 700 with a flex line 707.
  • the spacer material 700 may be similar to any of spacer material 100 in FIG. 1, spacer material 200 in FIG. 2, spacer material 300 in FIG. 3, spacer material 400 in FIG. 4, spacer material 500 in FIG. 5, or spacer material 600 in FIG. 6.
  • the spacer material 700 may comprise a spacer structure 701.
  • the spacer material 700 may comprise a fabric portion 702.
  • the flex line 707 may comprise a region of the spacer material 700 without the spacer structure 701.
  • the flex line 707 may comprise a material that is the same or similar material in the fabric portion 702.
  • the flex line 707 may comprise a different material than the material in the fabric portion 702 or the spacer structure 701.
  • the flex line 707 may comprise a less rigid material than in the fabric portion 702 or the spacer structure 701.
  • the flex line 707 may comprise a pocket, such as between two portions of the spacer structure 701 or between two fabric portions 702.
  • the spacer material 700 may be configured to bend or fold alone the flex line 707.
  • the spacer material 700 may bend or fold along the flex line 707 to enable packing or transport of the spacer material 700.
  • the spacer material 700 may be configured to drape along the flex line 707. Draping may comprise flexing or cascading over a body, such as without producing tight spots or rigidity.
  • FIG. 8 shows an example spacer material 800 with a hinge 808.
  • the spacer material 800 may be similar to any of spacer material 100 in FIG. 1, spacer material 200 in FIG. 2, spacer material 300 in FIG. 3, spacer material 400 in FIG. 4, spacer material 500 in FIG. 5, spacer material 600 in FIG. 6, or spacer material 700 in FIG. 7.
  • the spacer material 800 may comprise a spacer structure 801.
  • the spacer material 800 may comprise a fabric portion 802.
  • the hinge 808 may be a portion of the spacer material 800 that is not knit.
  • the hinge 808 may comprise a break in the spacer structure 801 or the fabric portion 802.
  • the spacer material 800 may be configured to bend or fold alone the hinge 808.
  • the spacer material 800 may be configured to bend or fold in one direction along the hinge 808.
  • the spacer material 800 may bend or fold along the hinge 808 to enable draping along the hinge 808. Draping may comprise flexing or cascading over a body, such as without producing tight spots or rigidity.
  • FIG. 9 shows an example spacer material 900 comprising a spacer structure 901 with a variable thickness.
  • FIG. 9a shows a side view of the example spacer material 900.
  • FIG. 9b shows a side view of the example spacer material 900.
  • the spacer material 900 may be similar to any of spacer material 100 in FIG. 1, spacer material 200 in FIG. 2, spacer material 300 in FIG. 3, spacer material 400 in FIG. 4, spacer material 500 in FIG. 5, spacer material 600 in FIG. 6, spacer material 700 in FIG. 7, or spacer material 800 in FIG. 8.
  • the spacer material 900 may comprise a fabric portion 902.
  • the thickness of the spacer structure 201 may range between 1-11 mm, 2-12 mm, or 3-13 mm, as examples.
  • the spacer structure 201 may be tapered.
  • the tapered portions may define channels 909.
  • the spacer material 900 may be configured to bend or fold about the channels 909.
  • the channels 909 or thinner portions of the spacer structure 901 may be configured to minimize the weight of the spacer material 900.
  • the thickness of portions of the spacer structure 901 may be selected based on desired properties of the spacer structure 901, the spacer material 900, or an article comprising the spacer material 900. For example, the thicker portions of the spacer structure 901 may be more rigid than the thinner portions of the spacer structure.
  • the thinner portions of the spacer structure 901 may comprise a different material than the thicker portions of the spacer structure 901.
  • the thicker portions of the spacer structure 901 may comprise a monofilament yam and the thinner portions of the spacer structure 901 may comprise spandex, tie yarn, or spacer yarn.
  • the thinner portions and the thicker portions of spacer structure 901 may comprise the same material.
  • the thinner portions and the thicker portions of spacer structure 901 may comprise different lengths of the same material, for example.
  • FIG. 10 shows an example spacer material 1000 comprising scoop structures 1009.
  • the spacer material 1000 may be similar to any of spacer material 100 in FIG. 1, spacer material 200 in FIG. 2, spacer material 300 in FIG. 3, spacer material 400 in FIG. 4, spacer material 500 in FIG. 5, spacer material 600 in FIG. 6, spacer material 700 in FIG. 7, spacer material 800 in FIG. 8, or spacer material 900 in FIG. 9.
  • the spacer material 1000 may comprise a spacer structure 1001.
  • the spacer material 1000 may comprise a fabric portion 1002.
  • the scoop structures 1009 may comprise a material that is the same as a material in the spacer structure 1001 or a material in the fabric portionl002.
  • FIG. lOa shows a side view of the example spacer material 1000.
  • FIG. lOb shows a perspective view of the example spacer material 1000.
  • the scoop structures 1009 may comprise a material that is different than a material in the spacer structure 1001 or a material in the fabric portion 1002.
  • the scoop structures 1009 may each comprise an open end 1010.
  • the scoop structures 1009 may each comprise a closed end 1011. As shown in FIG. 10, the open end 1010 may be have a greater height than the closed end 1011. Alternatively, the closed end 1011 may have a greater height than the open end 1010.
  • the scoop structures 1009 may all have similar structures or may comprise a mixture of structures.
  • Tension in the spacer material 1000 may cause the closed end 1011 to taper. The tension may be caused by a material in the spacer material 1000, such as spandex.
  • the scoop structures 1009 may be configured to facilitate air flow through the spacer material 1000. For example, air may enter through the open end 1010. After entering the open end 1010, the air may travel through the spacer structure 1001. As another example, air may exit through the open end 1010.
  • FIG. 11 shows an example spacer material 1100 comprising a shield 1111.
  • the spacer material 1100 may be similar to any of spacer material 100 in FIG. 1, spacer material 200 in FIG. 2, spacer material 300 in FIG. 3, spacer material 400 in FIG. 4, spacer material 500 in FIG. 5, spacer material 600 in FIG. 6, spacer material 700 in FIG. 7, spacer material 800 in FIG. 8, spacer material 900 in FIG. 9, or spacer material 1000 in FIG. 10.
  • the spacer material 1000 may comprise a spacer structure 1101.
  • the spacer material 1100 may comprise a fabric portion 1102
  • the shield 1111 may be disposed on a surface of the spacer structure 1101 that is opposite a surface of the spacer structure 1101 adjacent the fabric portion 1102.
  • the shield 1111 may be disposed on the fabric portion 1102.
  • the shield 1111 may comprise a film, such as a thermoplastic polyurethane (“TPU”) film or a polymer film.
  • the shield 1111 may comprise a chemical treatment on the spacer material 1100.
  • the shield 1111 may be bonded to the spacer material 1100, such as with an adhesive.
  • the shield 1111 may be coupled to the spacer material 1100 after the spacer material 1100 is knit.
  • the shield 1111 may be configured to resist water.
  • the shield 1111 may be configured to resist abrasion.
  • the shield may be placed selectively in regions of the spacer material 1100 based on a desired performance of the spacer material 1100 or of an article comprising the spacer material 1100.
  • the present disclosure comprises at least the following aspects.
  • a composite material comprising: a fabric spacer comprising a yam structure; and a first portion coupled (e.g., tied) to a first surface of the fabric spacer by the yarn structure.
  • Aspect 2 The composite material of claim 1, wherein the first portion comprises a warp knit portion, wherein the warp knit portion and the yam structure are knit
  • Aspect 3 The composite material of any one of aspects 1-2, further comprising a second portion coupled to a second surface of the fabric spacer by the yarn structure.
  • Aspect 4 The composite material of claim 3, wherein the second portion comprises a mesh fabric.
  • Aspect 5 The composite material of any one of aspects 1-4, wherein the yarn structure comprises a monofilament yarn.
  • Aspect 6 The composite material of any one of aspects 1-5, wherein the first portion comprises a multifilament yam.
  • Aspect 7 The composite material of any one of aspects 1-6, wherein the first portion comprises a plurality of loops. [0057] Aspect 8. The composite material of claim 7, wherein the first portion is coupled to the first surface of the yarn structure by at least a portion of the plurality of loops coupled to the yam structure.
  • Aspect 9 The composite material of any one of aspects 1-8, wherein the composite material is configured to absorb moisture and heat from a region external to the composite material.
  • Aspect 10 The composite material of any one of aspects 1-9, wherein the composite material is configured to maintain heat between the first portion and the fabric spacer.
  • Aspect 11 The composite material of any one of aspects 1-10, wherein the yarn structure comprises at least one of a polyester yarn, a spandex yam, or an elastane yarn.
  • Aspect 12 The composite material of any one of aspects 1-11, wherein the yarn structure comprises yarn with a thickness of 1-5 millimeters.
  • Aspect 13 The composite material of any one of aspects 1-11, wherein the yarn structure comprises yarn with a gauge of 25-30.
  • Aspect 14 The composite material of any one of aspects 1-13, wherein the yarn structure comprises a three-dimensional structure.
  • Aspect 15 The composite material of claim 14, wherein the three-dimensional structure comprises at least one of a sawtooth structure, a triangular structure, a rectangular structure, a curved structure, a crosshatch structure, a grated structure, or a wave structure.
  • Aspect 16 The composite material of any one of aspects 1-15, wherein the yarn structure has a uniform width.
  • Aspect 17 The composite material of any one of aspects 1-16, wherein the yarn structure has a width between 1-13 mm.
  • Aspect 18 The composite material of any one of aspects 1-17, wherein the composite material further comprises a flex line on the fabric spacer, wherein the composite material is configured to bend along the flex line.
  • Aspect 19 The composite material of any one of aspects 1-18, wherein the composite material comprises a plurality of scoop structures coupled to a second surface of the yarn structure.
  • Aspect 20 The composite material of any one of aspects 1-19, wherein the composite material comprises a water-resistant shield coupled to a portion of at least one of the first surface of the yam structure or a second surface of the yarn structure.
  • Aspect 21 The composite material of any one of aspects 1-20, wherein the composite material comprises an abrasion-resistant shield coupled to a portion of at least one of the first surface of the yam structure or a second surface of the yarn structure.
  • a method of manufacturing a composite material comprising: warp knitting a fabric spacer comprising a yarn structure; and warp knitting a first portion coupled to a first surface of the yam structure, wherein at least a portion of the fabric spacer and at least a portion of the first portion are knit contemporaneously.
  • Aspect 23 The method of aspect 22, wherein the warp knitting the first portion comprises warp knitting a plurality of loops, wherein at least a portion of the plurality of loops are coupled to at least a portion of the fabric spacer.
  • Aspect 24 The method of aspect 22, wherein the warp knitting the fabric spacer and the warp knitting the first portion comprise using a Raschel warp knitting machine.
  • Aspect 25 The method of any one of aspects 22-24, wherein the method further comprises warp knitting a second portion coupled to a second surface of the yam structure, wherein at least a portion of the second portion is knit contemporaneously with the at least a portion of the fabric spacer and the at least a portion of the first portion.
  • Aspect 26 The method of any one of aspects 22-24, wherein the method further comprises chemically treating at least a portion of at least one of the fabric spacer and the first portion.
  • Aspect 27 The method of any one of aspects 22-24, wherein the method further comprises mechanically treating at least a portion of at least one of the fabric spacer and the first portion.
  • Aspect 28 The method of any one of aspects 22-24, wherein the method further comprises coupling a water-resistant shield to at least one of the first surface of the yam structure of a second surface of the yarn structure.
  • Aspect 29 The method of any one of aspects 22-24, wherein the method further comprises coupling an abrasion-resistant shield to at least one of the first surface of the yarn structure of a second surface of the yam structure.
  • Aspect 30 An article of manufacture comprising a composite material, wherein the composite material comprises: a fabric spacer comprising a yarn structure; and a first portion coupled to a first surface of the yam structure.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Knitting Of Fabric (AREA)

Abstract

Un matériau composite peut comprendre un élément d'espacement de tissu comprenant une structure de fil et une première partie couplée à une première surface de l'élément d'espacement de tissu par la structure de fil. Le matériau composite peut être fabriqué par tricotage sur métier chaîne d'une ou de plusieurs parties couplées l'une à l'autre et/ou à l'élément d'espacement de tissu par la structure de fil. Les parties peuvent être tricotées sur métier chaîne et couplées simultanément.
PCT/US2019/021141 2018-03-07 2019-03-07 Matériaux composites et procédés de fabrication WO2019173583A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201862639848P 2018-03-07 2018-03-07
US62/639,848 2018-03-07

Publications (1)

Publication Number Publication Date
WO2019173583A1 true WO2019173583A1 (fr) 2019-09-12

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2019/021141 WO2019173583A1 (fr) 2018-03-07 2019-03-07 Matériaux composites et procédés de fabrication

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WO (1) WO2019173583A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113089168A (zh) * 2021-04-14 2021-07-09 太原理工大学 一种阻燃隔热玄武岩-阻燃纤维三维间隔机织物及其制造方法

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2001011127A1 (fr) * 1999-08-04 2001-02-15 Mothercare Uk Limited Ameliorations apportees ou relatives a des toiles d'espacement
US6627562B1 (en) * 1998-04-09 2003-09-30 Gehring Textiles, Inc. Blunt trauma reduction fabric for body armor
US20160263857A1 (en) * 2012-06-13 2016-09-15 Mueller Textiol Gmbh Knit spacer fabrics and motor-vehicle interior

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6627562B1 (en) * 1998-04-09 2003-09-30 Gehring Textiles, Inc. Blunt trauma reduction fabric for body armor
WO2001011127A1 (fr) * 1999-08-04 2001-02-15 Mothercare Uk Limited Ameliorations apportees ou relatives a des toiles d'espacement
US20160263857A1 (en) * 2012-06-13 2016-09-15 Mueller Textiol Gmbh Knit spacer fabrics and motor-vehicle interior

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113089168A (zh) * 2021-04-14 2021-07-09 太原理工大学 一种阻燃隔热玄武岩-阻燃纤维三维间隔机织物及其制造方法

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