WO2022175377A1

WO2022175377A1 - Multi-construction continuous double-sided knitted fabrics and methods of making

Info

Publication number: WO2022175377A1
Application number: PCT/EP2022/053918
Authority: WO
Inventors: Juergen Andreas KUNZMANN; Kara W. PRUITT
Original assignee: Bekaertdeslee Innovation Bvba
Priority date: 2021-02-17
Filing date: 2022-02-17
Publication date: 2022-08-25

Abstract

A continuously knitted spacer fabric is provided. The fabric includes at one or more fabric constructions, and the fabric constructions can include two or more knit, tuck, and float stitches. The fabric can be used in products such as mattress covers. To manufacture the fabric, needle pattern selections are made for each fabric construction a double selection circular knitting machine having three-way capabilities on one or both of the dial and the cylinder.

Description

MULTI-CONSTRUCTION CONTINUOUS DOUBLE-SIDED KNITTED FABRICS AND

METHODS OF MAKING

BACKGROUND

[0001] Textiles, such as those used in mattress covers, can benefit from multiple zones or constructions having different properties. Multi-zoned textiles are usually formed from sewing several constructions together, resulting in additional labor, waste, and creating ladders or seams. Continuously knitted textiles having multiple fabric construction zones can address these issues. These needs and other needs are satisfied by the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0002] Further aspects of the present disclosure will be more readily appreciated upon review of the detailed description of its various embodiments, described below, when taken in conjunction with the accompanying drawings.

[0003] Figure 1 is a camera image showing the internal construction of an example of a fabric in accordance with embodiments of the present disclosure.

[0004] Figure 2 is a camera image showing the various constructions in different zones of an example of a fabric in accordance with embodiments of the present disclosure.

[0005] The drawings illustrate only example embodiments and are therefore not to be considered limiting of the scope described herein, as other equally effective embodiments are within the scope and spirit of this disclosure. The elements and features shown in the drawings are not necessarily drawn to scale, emphasis instead being placed upon clearly illustrating the principles of the embodiments. Additionally, certain dimensions may be exaggerated to help visually convey certain principles. In the drawings, similar reference numerals between figures designate like or corresponding, but not necessarily the same, elements.

SUMMARY OF THE INVENTION

[0006] The present invention is directed to a fabric, wherein the fabric is a continuously knitted spacer fabric comprising a front side and a back side, wherein the fabric has at least two fabric portions, with each portion comprising a different fabric construction, and wherein each of the fabric constructions comprises different stretch and density properties from one another.

[0007] The fabric constructions are selected from two or more of:

• a construction comprising a combination of knit and tuck stitches;

• a construction comprising a combination of knit and float stitches; · a construction comprising a combination of knit, tuck, and float stitches.

[0008] As further detailed hereinafter, in a particular embodiment at least one of the selected fabric constructions comprise a monofilament yarn, wherein the tuck stitches are stitched with monofilament yarn. In a preferred embodiment the at least two different fabric constructions comprise a monofilament yarn, wherein the tuck stitches are stitched with monofilament yarn. The monofilament can be a polyester or a polyimide yarn having a denier of about 50 denier. In particular the monofilament is a polyester or a polyimide yarn having a denier of about 50 denier. More in particular the monofilament is a polyester yarn having a denier of about 50 denier

[0009] In the fabric constructions, said monofilament yarn can be combined with other materials. For example in the fabrics according to the invention at least one of the fabric constructions may comprise a monofilament yarn and a polyethylene yarn; in particular a polyethylene yarn having a denier of about 150 to 300; more in particular comprising a monofilament yarn and a cool-to- touch polyethylene yarn. In another example the at least one of the fabric constructions comprises a monofilament yard, a polyethylene yarn, and an additional yarn, wherein the additional yarn can be a textured polyester yarn, a synthetic spun yarn, a natural fibers, yarn, or combinations thereof. As further detailed in a particular embodiment according to the invention the additional yarn is a textured polyester yarn. In a preferred embodiment the ratio of polyethylene yarn to textured polyester is about 80:20.

[0010] In one of the fabric constructions of the fabric the monofilament yarn, may be combined with a polyethylene yarn, and a spun yarn. In one embodiment such fabric construction comprises a monofilament yarn, with a polyethylene yarn, and a spun yarn, wherein the ratio of polyethylene yarn to spun yarn is about 20:80.

[0011] In one of the fabric constructions of the fabric the monofilament yarn, may be combined with one or both of a filament polyester yarn and a spun yarn.

[0012] It will be evident that a fabric according to the invention may comprise one or more of the aforementioned fabric constructions comprising a monofilament yarn wherein within saif fabric construction the tuck stitches are stitched with monofilament yarn. One such fabric is a continuously knitted spacer fabric comprising a front side and a back side, wherein the fabric has at least two fabric portions, with each portion comprising a different fabric construction, and wherein at least one of the fabric constructions comprises a monofilament yarn with one or both of a filament polyester yarn and a spun yarn; and one of the fabric constructions comprises a monofilament yard, a polyethylene yarn, and an additional yarn, wherein the additional yarn can be a textured polyester yarn, a synthetic spun yarn, a natural fibers, yarn, or combinations thereof. The fabric according to the different embodiment of the invention wherein the back side is a weft knitted jacquard, being preferred. The herein described materials are particularly suitable as mattress cover. It is accordingly an object of the invention to provide a mattress cover comprising a fabric according to the different embodiments herein disclosed.

[0013] It is also an object of the invention in providing a method of making a continuously knitted spacer fabric on a double selection circular knitting machine, the method comprising:

• selecting a first pattern of needles to knit a front side of the fabric, wherein the pattern can comprise one or more of a tuck stitch, a float stitch, and a knit stitch;

• selecting a second pattern of needles to knit a back side of the fabric, wherein the pattern can comprise one or more of a tuck stitch, a float stitch, and a knit stitch;

• knitting a first fabric portion using the first and second pattern selections;

• selecting a third pattern of needles to knit a front side of the fabric, wherein the pattern can comprise one or more of a tuck stitch, a float stitch, and a knit stitch;

• selecting a fourth pattern of needles to knit a back side of the fabric, wherein the pattern can comprise one or more of a tuck stitch, a float stitch, and a knit stitch;

• knitting a second fabric portion using the third and fourth pattern selections.

[0014] The method my further comprising any one or all of; repeating the selecting and knitting steps to knit additional fabric portions, wherein the tuck stitches are knitted with a monofilament yarn, wherein the first and second portions have different fabric constructions.

[0015] It is stressed that the particulars in the aforementioned summary are by way of example and for purposes of illustrative discussion of the different embodiments of the present invention only. They are presented in the cause of providing what is believed to be the most useful and readily description of the principles and conceptual aspects of the invention. In this regard no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention. The description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice.

DETAILED DESCRIPTION

[0016] Before the present disclosure is described in greater detail, it is to be understood that this disclosure is not limited to particular embodiments described, and as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting, since the scope of the present disclosure will be limited only by the appended claims.

[0017] Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range, is encompassed within the disclosure. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges and are also encompassed within the disclosure, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the disclosure.

[0018] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present disclosure, the preferred methods and materials are now described.

[0019] As will be apparent to those of skill in the art upon reading this disclosure, each of the individual embodiments described and illustrated herein has discrete components and features which may be readily separated from or combined with the features of any of the other several embodiments without departing from the scope or spirit of the present disclosure. Any recited method can be carried out in the order of events recited or in any other order that is logically possible.

[0020] Embodiments of the present disclosure will employ, unless otherwise indicated, techniques of textiles engineering, material science, and the like, which are within the skill of the art.

[0021 ] The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how to perform the methods and use the materials disclosed and claimed herein. Efforts have been made to ensure accuracy with respect to numbers {e.g., amounts, temperature, etc.), but some errors and deviations should be accounted for. Unless indicated otherwise, parts are parts by weight, temperature is in °C, and pressure is at or near atmospheric.

[0022] Before the embodiments of the present disclosure are described in detail, it is to be understood that, unless otherwise indicated, the present disclosure is not limited to particular materials, as such can vary. It is also to be understood that the terminology used herein is for purposes of describing particular embodiments only, and is not intended to be limiting. It is also possible in the present disclosure that steps can be executed in different sequence where this is logically possible.

[0023] It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. [0024] In accordance with the purpose(s) of the present disclosure, as embodied and broadly described herein, embodiments of the present disclosure, in some aspects, relate to generally to knitted spacer fabrics having multiple fabric constructions in a single fabric.

[0025] In general, embodiments of the present disclosure provide for methods of making spacer fabrics having multiple constructions, spacer fabrics including multiple constructions, and products including the spacer fabrics.

[0026] The present disclosure includes a continuously knitted spacer fabric including multiple fabric constructions. Advantageously, the fabrics can have tunable breathability based on the combinations of construction zones.

[0027] Embodiments of the present disclosure include a continuously knitted spacer fabric as above including a front side and a back side. The knitted spacer fabric (hereinafter the fabric) can include a plurality of fabric constructions without seams between each of the fabric constructions, wherein the fabric constructions form zones having different characteristics. Each of the fabric constructions can have different properties, such as stretch and density, from one another.

[0028] The fabric described herein can made using a double selection circular knitting machine having three-way capabilities in one or both of the cylinder and dial. Three-way capabilities refer to the dial, the cylinder, or both being fitted to perform knit, float, and tuck stitches. The fabric can be made using a two-way (knit/float) dial and a three-way (knit/tuck/float) cylinder, a two- way (knit/float) cylinder and a three-way (knit/tuck/float) dial, or both a three-way dial and a three- way cylinder. In some embodiments, the needles of the knitting machine can be set such that the cylinder can knit the front side of the fabric and the dial can knit the back side of the fabric. In some embodiments, the needles can be set such that the dial can knit the front side of the fabric and the cylinder can knit the back side of the fabric.

[0029] The continuously knitted spacer fabrics described herein can be made by a series of steps. A first pattern of needles can be selected on either the cylinder or dial to knit a front side of the fabric. The pattern can comprise one or more of a tuck stitch, a float stitch, and a knit stitch. A second pattern of needles can be selected on respectively the dial or cylinder (opposite of the first pattern of needles) to knit a back side of the fabric. The pattern can comprise one or more of a tuck stitch, a float stitch, and a knit stitch. A first fabric portion can be knitted using the first and second pattern selections. A third pattern of needles can be selected on either the cylinder or dial to knit a front side of the fabric. The pattern can comprise one or more of a tuck stitch, a float stitch, and a knit stitch. A fourth pattern of needles can be selected on respectively the dial or cylinder (opposite of the first pattern of needles) to knit a back side of the fabric. The pattern can comprise one or more of a tuck stitch, a float stitch, and a knit stitch. A second fabric portion can be knitted using the third and fourth pattern selections. The selection and knitting steps can be repeated as many times as desired, with as many patterns as desired. The portions can be repeated or not repeated, according to need.

[0030] Each fabric construction zone is determined through a combination of the pattern of stitch combinations (knit/tuck/float) selected for the cylinder and the dial needles along with the materials used with each stitch combination. The fabric is continuously knitted, where the stitch pattern on the needles and the yarn combinations is adjusted for each zone without fabric takedown from the machine between constructions.

[0031] Advantageously, the continuous construction results in a seamless transition between fabric constructions, reducing uncomfortable seams and weak points. The absence of seams also removes the need for later sewing together different fabric constructions or waste associated with cutting and sewing multiple constructions together. Due to the lack of seams and the continuous construction, the fabric is also ladder resistant and does not include visible center lines, both of which are problems common to spacer and/or monofilament spacer constructions.

[0032] As mentioned above, the fabric can contain a plurality of fabric constructions without seams between each of the fabric constructions. The fabric can include one or more of the following construction types. In some embodiments, the fabric can include two or more of the following construction types. In a first construction, every needle in the dial and the cylinder has a tuck stitch and uses three-way technology on the cylinder or dial to form a stitch in combination with a dial tuck stitch. When the cylinder or dial needle using the three-way technology forms such a stitch no tuck stitch is held on this particular needle. In a second construction, every needle in dial and cylinder has a tuck stitch and on the following knit feeders a combination of knit, tuck, and float stitches can be used. In a third construction, every needle in dial and cylinder has a tuck stitch, and a combination of knit and tuck stitches can be used. In some embodiments, the construction can include knitting both layers together in certain areas to create a deep effect, resulting in a quilting appearance. Each of the construction types can have multiple subtypes and fiber and/or filament arrangements. Described differently, desired design and fabric properties can be created by selecting each needle to make a tuck, knit, or float on the cylinder and/or the dial for each desired yarn or filament combination.

[0033] In some embodiments, the fabric is a continuously knitted spacer fabric including a front side and a back side, with the fabric having at least two fabric portions, with each portion comprising a different fabric construction. Each of the fabric constructions can have different stretch and density properties from one another. The fabric constructions can be selected from: a combination of knit and tuck stitches; a combination of knit and float stitches, and a construction comprising a combination of knit, tuck, and float stitches.

[0034] The materials used for each fabric construction type above can be selected based on the desired characteristics of the zone. In construction types that include a tuck stitch, the tuck yarn can be a monofilament in example embodiments. The monofilament can be a polyester or a polyimide having a denier of about 30 to 100. In particular the monofilament is a polyester. In a particular embodiment, the monofilament is about 50 denier. The denier of the monofilament and the amount and length of monofilament stitches can be selected to tune the resilience of the fabric. A larger amount of monofilament in the knitted fabric results in more resilience. The monofilament can be colored or uncolored.

[0035] In some embodiments, a fabric construction can include a monofilament combined with a cool-to-touch yarn (e.g. a filament yarn). The cool-to-touch yarn can be a cool-to-touch polyethylene yarn having a denier of about 150 to 300, or about 300 denier. In one embodiment the cool-to-touch polyethylene yarn can be a ultra-heigh weight molecular polyethylene yarn. Ultra-high weight molecular polyethylene may also be referred to as high-modulus polyethylene or high-performance polyethylene. Ultra-high weight molecular polyethylene has extremely long chains. Ultra-high weight molecular polyethylene is a type of polyolefin having a melting point of about 130° C. to about 136° C. (266° F. to 277° F.). Ultra-high weight molecular polyethylene has very high thermal conductivity properties that feel cool to the touch. Ultra-high weight molecular polyethylene provides thermal conduction while transferring heat away from a user's body. Heat flows from source to sink, such as, for example, from a warmer or hotter body to a cooler or colder body. When used in bedding, the hotter body is the human body and the colder body is a fabric the bedding is made from, the fabric comprising ultra-high weight molecular polyethylene. Ultra-high weight molecular polyethylene has a very high rate of thermal conduction, which creates a temperature differential/gradient between the human body and a surface of the fabric, thus allowing heat to diffuse from the human body to the fabric. Over time temperature differences decay and a thermal equilibrium is achieved to help the user achieve a restful sleep with long lasting cooling.

In some embodiments, the fabric construction can include a monofilament combined with a cool- to-touch yarn (e.g. a filament yarn), a cool-to-touch yarn, in particular a polyethylene yarn as herein disclosed and a textured polyester. Such combination will improve the heat diffusion from the human body to the fabric. Compared to regular polyester, the cross-section of a textured polyester fiber is different. The cross section of a regular polyester is circular, rod like appearance with a uniform diameter while the textured moisture wicking polyester fibers cross section has ditches/grooves e.g. star shape. The ditches/grooves provide spaces between the polymers that create channels for fast moisture wicking, which speeds up the moisture absorption and diffusion, and accordingly contribute to an improved heat diffusion. The textured polyester can have a denier of about 100 to 150. In some embodiments, the ratio of polyethylene yarn to textured polyester can be about 80:20. In other embodiments, the ratio can be from about 1 :99 to 99:1 . Advantageously, the combination of monofilament tuck stitches and cool-to-touch yarn or monofilament tuck stitches and cool-to-touch yarn and textured polyester yarn can provide a cool-feel surface. The pattern and number of tuck stitches can determine the breathability of the fabric construction.

[0036] In place of the monofilament, any other filament, synthetic fiber and/or natural yarn can be substituted. However, the properties of resilience, airflow and breathability will be impacted by not using monofilament.

[0037] In some embodiments, a fabric construction can include a monofilament combined with a polyethylene yarn and a spun yarn. The polyethylene yarn can have a denier of about 150 to 300, or about 300 denier. The spun yarn can be a natural fiber yarn (e.g. cotton, wool, tencel, micromodal, bamboo) or a synthetic polyspun yarn. In some embodiments, the ratio of polyethylene yarn to spun yarn can be about 20:80. Other ratios are also possible.

[0038] In some embodiments, a fabric construction can include a monofilament combined with or substituted with other synthetic yarns. For example, the construction can include such as any of the following: monofilament and/or other synthetic yarns in combination with cool to touch yarns; monofilament and/or other synthetic yarns in combination with both cool to touch yarns and texturized polyester yarns; monofilament and/or other synthetic yarns in combination with cool to touch yarns and spun yarns; monofilament and/or other synthetic yarns in combination with cool to touch yarns and filament yarns; monofilament and/or other synthetic yarns in combination with filament polyester yams; monofilament and/or other synthetic yarns in combination with filament polyester yarns and/or any kind of spun yarn. When reference is made to the monofilament, it is meant to include the monofilaments as herein described, including the possible combinations with a cool-to-touch yarn, in particular a polyethylene yarn as herein disclosed and/or a textured polyester.

[0039] In some embodiments, a fabric construction can include a monofilament combined with a filament polyester yarn and a spun yarn as described above. When reference is made to the monofilament, it is meant to include the monofilaments as herein described, including the possible combinations with a cool-to-touch yarn, in particular a polyethylene yarn as herein disclosed and/or a textured polyester.

[0040] In some embodiments, the fabric construction can include a fire-retardant yarn in combination with any of the above constructions, in an amount sufficient to pass the CFR 1633 burn test for mattresses.

[0041] In some embodiments, the back side can be weft knitted jacquard.

[0042] In some embodiments, the fabric can have a weight of about 250 gsm. In some embodiments, the fabric can have a weight of about 330 gsm. In other embodiments, a higher weight can be achieved by changing the stitch ratio. In some embodiments, the fabric can have a shrinkage of about 5% to 6% when washed. In other embodiments, the fabric can have a shrinkage of less than about 10%. In still other embodiments, the fabric can have a shrinkage of less than about 6%.

[0043] In some embodiments the fabric can be used in products such as a mattress cover or mattress ticking. Advantageously, one side or both sides of the fabric can be used as the sleep surface. The fabric can be reversable and the inside of the mattress cover can be turned to the outside. In a particular embodiment, one side of the fabric can be used as a “summer side” such as by including cool-to-touch yarns as described above and the other side can be used as a “winter side” such as by including warmer yarn (e.g. spun yarns as described above).

[0044] Advantageously, different zones for a different amount of breathability can be achieved and can be placed in predetermined areas, such as where the human body touches the sleep surface.

[0045] In some embodiments, the fabric can be knitted to a width of up to about 107 inches (up to about 3 m), which is sufficient to wrap an entire mattress core. In other embodiments, the fabric can have a width appropriate for other sizes, such as about 88 inches (about 2,3 m), about 92 inches (about 2,4 m), or about 100 inches (about 2.5 m). Advantageously, labor costs and waste can be reduced because that no additional fabric is needed for tasks such as sewing on the top panel to cover the border area.

[0046] Advantageously, the fabric can include multiple colorways and almost unlimited pattern possibilities due to the many possible iterations of knit/tuck/float combinations, yarn and filament combinations, and color ways for each.

[0047] Figure 1 shows the air ventilating space between the front and back sides of the fabric construction. The back side is in the top of the image, and the front side is at the bottom.

[0048] Figure 2 shows a knit textile having three construction zones. The left zone (white) is a high ventilation area having holes formed by a knit and tuck pattern, with no knit stiches on the back side of the fabric. The middle zone (black with gray stripes) includes a monofilament knit stitch, visible as gray stripe. The right zone (white and gray marl) is a mixed yarn zone. The knit textile has been continuously formed as described above, such that the fabric was knitted containing the three construction zones, rather than each zone being formed separately and sewn together later.

[0049] In some embodiments, an elastic yarn can be added to the back and/or front side of the fabric. A bi-axial stretch up to about 50% can be achieved. Such stretch can be advantageous, such as when the fabric is used as a mattress cover on a bed with an adjustable bed base. [0050] It should be noted that ratios, concentrations, amounts, and other numerical data may be expressed herein in a range format. It is to be understood that such a range format is used for convenience and brevity, and thus, should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. To illustrate, a concentration range of “about 0.1% to about 5%” should be interpreted to include not only the explicitly recited concentration of about 0.1 wt% to about 5 wt%, but also include individual concentrations (e.g., 1%, 2%, 3%, and 4%) and the sub-ranges (e.g., 0.5%, 1.1%, 2.2%, 3.3%, and 4.4%) within the indicated range. In an embodiment, “about 0” can refer to 0, 0.001 , 0.01 , or 0.1. In an embodiment, the term “about” can include traditional rounding according to significant figures of the numerical value. In addition, the phrase “about 'x' to ‘y’” includes “about ‘x’ to about ‘y’”.

Aspects of the Disclosure

[0051] The present disclosure will be better understood upon reading the following numbered aspects, which should not be confused with the claims. Any of the numbered aspects below can, in some instances, be combined with aspects described elsewhere in this disclosure and such combinations are intended to form part of the disclosure.

[0052] Aspect 1. A fabric, wherein the fabric is a continuously knitted spacer fabric comprising a front side and a back side, wherein the fabric has at least two fabric portions, with each portion comprising a different fabric construction, and wherein each of the fabric constructions comprises different stretch and density properties from one another.

[0053] Aspect 2. The fabric of aspect 1 , wherein the fabric constructions are selected from two or more of: a construction comprising a combination of knit and tuck stitches; a construction comprising a combination of knit and float stitches; a construction comprising a combination of knit, tuck, and float stitches.

[0054] Aspect 3. The fabric of aspect 2, wherein at least one of the selected fabric constructions comprise a monofilament yarn, wherein the tuck stitches are stitched with monofilament yarn.

[0055] Aspect 4. The fabric of aspect 3, wherein the monofilament is a polyester or a polyimide yarn having a denier of about 50 denier.

[0056] Aspect 5. The fabric of aspect 3, wherein at least one of the fabric constructions comprises a monofilament yard and a polyethylene yarn having a denier of about 150 to 300. [0057] Aspect 6. The fabric of aspect 3, wherein at least one of the fabric constructions comprises a monofilament yard, a polyethylene yarn, and an additional yarn, wherein the additional yarn can be a textured polyester yarn, a synthetic spun yarn, a natural fibers, yarn, or combinations thereof.

[0058] Aspect 7. The fabric of aspect 6, wherein the ratio of polyethylene yarn to textured polyester is about 80:20.

[0059] Aspect 8. The fabric of aspect 3, wherein at least one of the fabric constructions comprises a monofilament yarn, a polyethylene yarn, and a spun yarn.

[0060] Aspect 9. The fabric of aspect 8, wherein the ratio of polyethylene yarn to spun yarn is about 20:80.

[0061] Aspect 10. The fabric of aspect 3, wherein at least one of the fabric constructions comprises a monofilament yarn with one or both of a filament polyester yarn and a spun yarn. [0062] Aspect 11. The fabric of aspect 1 , wherein the back side is a weft knitted jacquard.

[0063] Aspect 12. A mattress cover comprising a fabric according to any of aspects 1-11.

[0064] Aspect 13. A method of making a continuously knitted spacer fabric on a double selection circular knitting machine, the method comprising: selecting a first pattern of needles to knit a front side of the fabric, wherein the pattern can comprise one or more of a tuck stitch, a float stitch, and a knit stitch; selecting a second pattern of needles to knit a back side of the fabric, wherein the pattern can comprise one or more of a tuck stitch, a float stitch, and a knit stitch; knitting a first fabric portion using the first and second pattern selections; selecting a third pattern of needles to knit a front side of the fabric, wherein the pattern can comprise one or more of a tuck stitch, a float stitch, and a knit stitch; selecting a fourth pattern of needles to knit a back side of the fabric, wherein the pattern can comprise one or more of a tuck stitch, a float stitch, and a knit stitch; knitting a second fabric portion using the third and fourth pattern selections.

[0065] Aspect 14. The method of aspect 13, further comprising repeating the selecting and knitting steps to knit additional fabric portions.

[0066] Aspect 15. The method of aspect 14, wherein the tuck stitches are knitted with a monofilament yarn.

[0067] Aspect 16. The method of aspect 13, wherein the first and second portions have different fabric constructions. [0068] It should be emphasized that the above-described embodiments of the present disclosure are merely possible examples of implementations, and are set forth only for a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described embodiments of the disclosure without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure.

Claims

1. A fabric, wherein the fabric is a continuously knitted spacer fabric comprising a front side and a back side, wherein the fabric has at least two fabric portions, with each portion comprising a different fabric construction, and wherein each of the fabric constructions comprises different stretch and density properties from one another.

2. The fabric of claim 1 , wherein the fabric constructions are selected from two or more of:

• a construction comprising a combination of knit and tuck stitches;

• a construction comprising a combination of knit and float stitches;

• a construction comprising a combination of knit, tuck, and float stitches.

3. The fabric of claim 2, wherein at least one of the selected fabric constructions comprise a monofilament yarn, wherein the tuck stitches are stitched with monofilament yarn.

4. The fabric of claim 3, wherein the monofilament is a polyester or a polyimide yarn having a denier of about 50 denier.

5. The fabric of claim 3, wherein at least one of the fabric constructions comprises a monofilament yarn and a polyethylene yarn; in particular a polyethylene yarn having a denier of about 150 to 300; more in particular comprising a monofilament yarn and a cool- to-touch polyethylene yarn.

6. The fabric of claim 3, wherein at least one of the fabric constructions comprises a monofilament yard, a polyethylene yarn, and an additional yarn, wherein the additional yarn can be a textured polyester yarn, a synthetic spun yarn, a natural fibers, yarn, or combinations thereof.

7. The fabric of claim 3, wherein the additional yarn is a textured polyester yarn.

8. The fabric of claim 7, wherein the ratio of polyethylene yarn to textured polyester is about

80:20.

9. The fabric of claim 3, wherein at least one of the fabric constructions comprises a monofilament yarn, a polyethylene yarn, and a spun yarn.

10. The fabric of claim 9, wherein the ratio of polyethylene yarn to spun yarn is about 20:80.

11. The fabric of claim 3, wherein at least one of the fabric constructions comprises a monofilament yarn with one or both of a filament polyester yarn and a spun yarn.

12. The fabric of claim 3, wherein at least one of the fabric constructions comprises a monofilament yarn with one or both of a filament polyester yarn and a spun yarn; and one of the fabric constructions comprises a monofilament yard, a polyethylene yarn, and an additional yarn, wherein the additional yarn can be a textured polyester yarn, a synthetic spun yarn, a natural fibers, yarn, or combinations thereof.

13. The fabric of claim 1, wherein the back side is a weft knitted jacquard.

14. A mattress cover comprising a fabric according to any of claims 1 -13.

15. A method of making a continuously knitted spacer fabric on a double selection circular knitting machine, the method comprising:

16. The method of claim 15, further comprising repeating the selecting and knitting steps to knit additional fabric portions.

17. The method of claim 16, wherein the tuck stitches are knitted with a monofilament yarn.

18. The method of claim 17, wherein the first and second portions have different fabric constructions.