HK40003649B - Garment with zoned insulation and variable air permeability - Google Patents

Description

Garments with zoned insulation and variable breathability

Field of the Invention

The present disclosure relates to a garment having insulation zones with variable breathability properties.

Background of the Invention

Garments constructed for use in cold weather typically use some type of insulating material to provide warmth to the wearer. The insulating material is typically evenly distributed throughout the garment.

This disclosure relates to the following aspects:

1). A garment comprising a first garment portion formed from a first material having a first surface and a second surface, the first material being formed using at least a first yarn, a second yarn, and a third yarn, the first yarn being dimensionally stable when exposed to a physical stimulus, the second yarn exhibiting a dimension change when exposed to the physical stimulus, the second yarn being interlaced with the first yarn so that the first yarn roughly forms the first surface of the first material and the second yarn is roughly positioned below the first yarn, the third yarn forming the second surface of the first material, the third yarn being mechanically manipulated to form a plurality of protrusions extending from the second surface, each of the plurality of protrusions having an end portion positioned relative to the first material.

2). The garment according to 1), wherein the first material comprises a knitted material, and wherein the first surface of the first material constitutes an outward-facing surface of the garment, and wherein the second surface of the first material constitutes an inward-facing surface of the garment.

3) The garment according to 2), wherein the first yarn comprises 50% conventional polyester fiber or silk and 50% cationic dyeable polyester fiber or silk.

4). The garment according to 3), wherein the second yarn is a bicomponent yarn formed of nylon-6 fiber or silk and cationic dyeable polyester fiber or silk.

5) The garment according to 4), wherein the second yarn comprises 50% nylon-6 fiber or silk and 50% cationic dyeable polyester fiber or silk.

6). The garment according to 2), wherein the third yarn is dimensionally stable when exposed to the physical stimulus.

7). The garment according to 6), wherein the third yarn comprises 100% polyester fiber or silk.

8). The garment according to 2), wherein the first garment portion exhibits a first air permeability when not exposed to the physical stimulus, and wherein the first garment portion exhibits a second air permeability when exposed to the physical stimulus, the first air permeability being less than the second air permeability.

9). A knitted fabric comprising:

a first surface and an opposing second surface;

a first yarn that is dimensionally stable when exposed to water;

a second yarn that exhibits a dimensional change upon absorbing water, the second yarn being plated with the first yarn such that the first yarn generally forms the first surface of the knit fabric and the second yarn is positioned generally beneath the first yarn; and

A third yarn forms the second surface of the knitted fabric, the third yarn being mechanically manipulated to form a plurality of projections extending from the second surface, each of the plurality of projections having a terminal end positioned opposite the second surface.

10) The knitted fabric according to 9), wherein the knitted fabric comprises a single jersey fabric, and wherein the plurality of protrusions comprise French terry.

11). The knitted fabric according to 9), wherein the third yarn is dimensionally stable when exposed to water.

12) The knitted fabric according to 9), wherein the second yarn constitutes 20% to 30% of the knitted fabric.

13) The knitted fabric according to 9), wherein the knitted fabric exhibits a first air permeability when not exposed to water and exhibits a second air permeability when exposed to water, wherein the first air permeability is smaller than the second air permeability.

14). The knitted fabric according to 9), wherein the plurality of protrusions are positioned adjacent to each other in a mosaic pattern.

15). The knitted fabric according to 14), wherein side portions of the plurality of protrusions are substantially perpendicular to a surface plane of the second surface of the knitted fabric.

16). A garment comprising a torso region, the torso region having at least a front region, a back region, a first arm opening and a second arm opening, a first side region and a second side region, the first side region extending from near the first arm opening to near the waist opening of the garment, and the second side region extending from near the second arm opening to near the waist opening of the garment; wherein at least a first portion of the garment is formed by a first material having a first surface and a second surface, the first material comprising a knitted material formed using at least a first yarn, a second yarn and a third yarn, the first yarn being dimensionally stable when exposed to a physical stimulus, the second yarn exhibiting a dimension change when exposed to the physical stimulus, the second yarn forming a tacking with the first yarn so that the first yarn roughly forms the first surface of the first material, and the second yarn is roughly positioned below the first yarn, the third yarn being dimensionally stable when exposed to the physical stimulus, the third yarn forming the second surface of the first material, the third yarn being mechanically operated to form a plurality of protrusions extending from the second surface, each of the plurality of protrusions having an end portion positioned relative to the first material.

17). The garment according to 16), wherein the first surface of the first material constitutes an outward-facing surface of the first material, and wherein the second surface of the first material constitutes an inward-facing surface of the first material.

18) The garment according to 17), wherein the first portion of the garment is positioned at least in the vertical direction along a central portion of the rear region of the garment.

19). The garment according to 16), wherein the first material exhibits a first air permeability when not exposed to the physical stimulus, and wherein the first material exhibits a second air permeability when exposed to the physical stimulus, the second air permeability being greater than the first air permeability.

20). The garment according to 19), wherein the second air permeability is at least 25% greater than the first air permeability.

BRIEF DESCRIPTION OF THE DRAWINGS

Examples of the present invention are described in detail below with reference to the accompanying drawings, in which:

FIG1 illustrates an exemplary knitted structure according to aspects herein;

FIG. 2 illustrates an exemplary adaptive yarn according to aspects herein;

FIG3A illustrates an exemplary knit structure using adaptive yarn according to aspects herein when not exposed to a physical stimulus;

FIG3B illustrates the exemplary knit structure of FIG3A when exposed to a physical stimulus according to aspects herein;

FIG4 illustrates a first surface of an exemplary fabric incorporating the exemplary knit structure of FIG1 according to aspects herein;

FIG5 illustrates an opposite second surface of the exemplary fabric of FIG4 according to aspects herein;

FIG6 illustrates a cross-section taken along section line 6-6 of FIG5 according to aspects herein;

FIG. 7 illustrates a front view of an exemplary garment incorporating the exemplary fabrics of FIG. 4 and FIG. 5 according to aspects herein;

FIG8 illustrates a rear view of the exemplary garment of FIG7 according to aspects herein;

FIG. 9 illustrates the example garment of FIG. 7 in an open position such that the interior of the garment is shown, according to aspects herein;

10 and 11 illustrate front and back perspective views of an exemplary garment incorporating the exemplary fabric of FIGS. 4 and 5 and according to aspects herein;

12 and 13 illustrate front and back perspective views of an exemplary garment incorporating the exemplary fabric of Figs. 4 and 5 according to aspects herein; and

14 illustrates an alternative exemplary protrusion shape for the opposing second surface of the exemplary fabric of FIG. 4 according to aspects herein.

Detailed Description of the Invention

The subject matter of the present invention is described in detail herein to meet statutory requirements. However, the description itself is not intended to limit the scope of the present disclosure. Rather, the inventors have contemplated that the claimed or disclosed subject matter may also be embodied in other ways in conjunction with other existing or future technologies, to include different steps or combinations of steps similar to the steps described in this document. Furthermore, although the terms "step" and/or "box" may be used herein to refer to different elements of the method used, these terms should not be interpreted as implying any particular order among or between the various steps disclosed herein, unless and except when the order of the individual steps is explicitly stated.

At a high level, aspects of the present disclosure relate to a fabric knitted with an adaptive yarn that combines thermal insulation characteristics with variable breathability characteristics. For example, the adaptive fabric can exhibit a baseline level of thermal insulation. Similarly, the adaptive fabric is configured to exhibit a first breathability when not exposed to a physical stimulus (e.g., water), and a second breathability when exposed to the physical stimulus, wherein the second breathability is greater than the first breathability. As used throughout this disclosure, the term "water" is intended to include substances such as sweat or perspiration. In an exemplary aspect, the knitted fabric comprises a single knit jersey having terry loops on one surface of the fabric.

More specifically, the adaptive fabric is formed using at least a first yarn, a second yarn, and a third yarn, wherein the first yarn is dimensionally stable when exposed to a physical stimulus (e.g., water), the second yarn changes dimensionally when exposed to the physical stimulus, and the third yarn is dimensionally stable when exposed to the physical stimulus. In an exemplary aspect, the first yarn is knitted to form a first surface of the fabric, and the second yarn is plated with the first yarn so that it is positioned approximately below the first yarn in the knitted fabric. The third yarn is mechanically manipulated to form loops that form the opposite second surface of the fabric. In an exemplary aspect, the loops are gathered together to form discrete protrusions that extend away from the second surface of the fabric (i.e., extend in the z-direction). In one aspect, the protrusions can have end portions located opposite the surface plane of the fabric. The protrusions can be arranged in a tessellation pattern that maximizes the number of protrusions per unit area, and spaces can be formed between adjacent protrusions.

When an adaptive fabric is incorporated into a garment, such as one configured for cold weather conditions, the fabric can be strategically positioned on the garment so that, when the garment is worn, it is positioned adjacent to, for example, areas of high heat or sweat generation on the wearer. The second surface can constitute the garment's inward-facing surface, and the first surface can contribute to the garment's outward-facing surface. This way, when the garment is worn, the protrusions formed by the loops can contact or nearly contact the wearer's body, helping to keep heated air generated by the wearer in contact with the wearer's body. Due to the large surface area of the protrusions created by the use of the loops, the protrusions can help "trap" heated air and reduce the chance of heated air being directed away from the wearer's body. This is helpful when the wearer is resting or generating minimal body heat. However, when the wearer begins to sweat, for example due to exercise or rising temperatures, the protrusions can help transport sweat to the second yarn, causing it to undergo a dimensional change from a coiled state to a straight or flat state. This results in an increase in the size of the openings formed between the yarn loops, which in turn increases the fabric's breathability. The increase in breathability can help dissipate heat and/or moisture vapor generated by the wearer and thereby cool the wearer. The result is a garment that can provide insulation when needed, such as when the wearer is resting, and cooling when needed, such as when the wearer is active or exercising.

Thus, aspects of the present invention relate to a garment comprising a first garment portion formed from a first material having a first surface and a second surface. The first material is formed using at least a first yarn and a second yarn, the first yarn being dimensionally stable when exposed to water and the second yarn exhibiting a dimensional change when absorbing water, wherein the second yarn is plated with the first yarn such that the first yarn substantially forms the first surface of the first material and the second yarn is positioned substantially below the first yarn. The first material is further formed using a third yarn, the third yarn forming the second surface of the first material. The third yarn is mechanically manipulated to form a plurality of protrusions extending from the second surface, wherein each of the plurality of protrusions has a terminal end located opposite the second surface of the first material.

In another aspect, a knitted fabric is provided. The knitted fabric includes a first surface and an opposing second surface, a first yarn that is dimensionally stable when exposed to water, and a second yarn that exhibits a dimensional change when absorbing water, wherein the second yarn is plated with the first yarn such that the first yarn substantially forms the first surface of the fabric and the second yarn is positioned substantially beneath the first yarn. The knitted fabric also includes a third yarn that forms the second surface of the first material, wherein the third yarn is mechanically manipulated to form a plurality of protrusions extending from the second surface, wherein each of the plurality of protrusions has a terminal end located opposite the second surface.

In yet another aspect, a garment is provided. The garment includes a torso region having at least a front region, a back region, a first arm opening, a second arm opening, a first side region, and a second side region, the first side region extending from proximate the first arm opening to proximate the waist opening of the garment, and the second side region extending from proximate the second arm opening to proximate the waist opening of the garment, wherein when the garment is in a worn configuration, at least the front region, the back region, and the first and second side regions are adapted to cover the torso of a wearer. At least a first portion of the garment is formed from a first material having a first surface and a second surface, wherein the first material comprises a knitted material formed using at least a first yarn and a second yarn, the first yarn being dimensionally stable when exposed to water and the second yarn exhibiting dimensional change upon absorbing water. The second yarn is plated with the first yarn such that the first yarn substantially forms the first surface of the first material and the second yarn is positioned substantially below the first yarn. The knitted material is further formed using a third yarn that is dimensionally stable when exposed to water, wherein the third yarn forms the second surface of the first material. The third yarn is mechanically manipulated to form a plurality of projections extending from the second surface, wherein each of the plurality of projections has a terminal end located opposite the second surface of the first material.

As used throughout this disclosure, directional terms such as front, back, side, anterior, posterior, upper, lower, inwardly facing, outwardly facing, and the like, will be given their ordinary meaning relative to a garment intended to be worn by a wearer standing in an anatomical posture. Terms such as "configured to cover [a specified body part of the wearer]" will be interpreted with respect to a garment that is appropriately sized for a particular wearer. Terms such as "proximate" mean within 0.5 cm to 40 cm of the indicated area.

Turning now to FIG. 1 , an exemplary knitted structure 100 according to aspects of the present invention is provided. Compared to, for example, a woven structure, due to the interconnected looping properties of the knitted structure (interlooping nature), the use of a knitted structure as described herein can inherently provide a higher level of baseline breathability. In other words, compared to a woven structure, a knitted structure can inherently have a larger number of spaces and/or a larger surface area of spaces formed between the knitted loops. The knitted structure 100 is formed using at least a first yarn 110, a second yarn 112 and a third yarn 114 that form a plaited yarn with the first yarn 110. In an exemplary aspect, the first yarn 110 can include a yarn that is dimensionally stable when exposed to physical stimuli such as water, elevated temperatures, wind, light energy, magnetic energy, and the like. In other words, when exposed to physical stimuli, the first yarn 110 does not experience a measurable change in size or properties (i.e., for example, length, thickness, crimp). In an exemplary aspect, the first yarn 110 can comprise a 20 gauge, 150 denier, 144 filament semi-dull heather polyester yarn. A formulation for the fiber or filament content of the first yarn 110 can comprise, for example, 50% conventional non-absorbent polyester and 50% cationic dyeable polyester yarn, which is also non-absorbent. Other formulations for the fiber or filament content of the first yarn 110 are contemplated herein. Likewise, other non-absorbent polymer fibers or filaments, such as rayon, nylon, polyacrylic, and the like, are also contemplated herein.

Second yarn 112 may include yarn that changes dimensionally (i.e., undergoes changes in length, thickness, crimp, and the like) when exposed to a physical stimulus such as water (liquid or gaseous), elevated temperature, flowing air, light energy, magnetic energy, and the like. Exemplary yarns may be manufactured by Teijin Fiber Co., Ltd. of Japan. With respect to water, dimensional changes due to, for example, immersion or contact with liquid water may occur relatively quickly (e.g., under 30 seconds). Alternatively, such changes may occur more slowly due to prolonged exposure to air with a relative humidity above, for example, 75%.

In an exemplary aspect, the second yarn 112 can include a 20 gauge 75 denier/24 filament semi-dull bicomponent yarn or a 50 denier/24 filament semi-dull bicomponent yarn. In an exemplary aspect, the 75 denier/24 filament yarn can exhibit less curl than the 50 denier/24 filament yarn, but can exhibit higher stability (i.e., longer shelf life). The fiber or filament content of the second yarn 112 can be formulated to include, for example, 50% non-absorbent modified cationic dyeable polyester and 50% hygroscopic polycaprolactam or nylon-6. In an exemplary aspect, the second yarn 112 is formed using an air mixing process to combine polycaprolactam fibers or filaments with modified cationic dyeable polyester fibers or filaments. Typically, polycaprolactam or nylon-6 exhibits a moisture regain of approximately 4.1%, while modified cationic dyeable polyester fibers or filaments may exhibit a moisture regain of 0.2-0.4%, where moisture regain can be defined as the weight of water in a material as a percentage of its oven-dried weight. Thus, the use of these two types of fibers or filaments allows the difference in moisture regain to be sufficient to cause dimensional changes in the second yarn 112. Fifty percent of the modified cationic dyeable polyester fibers or filaments and 50% of the hygroscopic polycaprolactam or nylon-6 fibers or filaments are arranged in a generally side-by-side manner with minimal twist between the different fiber/filament groups to produce a yarn having a generally circular cross-section.

In an exemplary aspect, the cation dyeable polyester fiber or the silk in the second yarn 112 are modified so that they will better adhere to polycaprolactam or nylon-6 fiber or silk. In an exemplary aspect, the cation dyeable polyester fiber or the silk can be modified by increasing the quantity of cation and anion. Compared with traditional cation dyeable polyester fiber or silk, higher cationic content can cause the larger adhesion amount to polycaprolactam or nylon-6 fiber or silk. This and then can reduce melt temperature, and can reduce the degree of crystallinity of modified cation dyeable polyester fiber or silk. Because of this, compared with the cation dyeable polyester fiber or the silk used in the first yarn 110 and/or the 3rd yarn 114, the cation dyeable polyester fiber or the silk in the second yarn 112 can show the larger affinity to dyestuff (disperse dye and cationic dye). In other words, the modified cation dyeable polyester fiber or the silk in the second yarn 112 can absorb dyestuff to a greater extent than the first yarn 110 or the 3rd yarn 114, and therefore look darker than these yarns after dyeing.

Next, to address the color difference between first yarn 110 and second yarn 112 after dyeing, for example, a heather yarn may be used for first yarn 110. To help understand this, and as will be explained further below, after being incorporated into a fabric, first yarn 110 may form, for example, the fabric's outward-facing surface. Furthermore, first yarn 110 and second yarn 112 form a plaited yarn. However, due to imperfections in the plaiting process, second yarn 112 may occasionally be visible on the fabric's outward-facing surface. Using a heather yarn for first yarn 110 helps mask, disguise, or conceal the darker-dyed second yarn 112 because the heathered yarn has lighter and darker areas.

Other formulations for the fiber or filament content of second yarn 112 are contemplated herein, such as: 1) 70% non-absorbent polyester and 30% hygroscopic polyester; 2) 80% non-absorbent polyester and 20% hygroscopic polyester; 3) 80% typically non-absorbent, cationic-dyeable polyester and 20% hygroscopic polyester, and the like. As can be seen, the percentage of fibers or filaments formed from hygroscopic materials can vary considerably within the scope of the various aspects herein. In each of the examples provided above, non-absorbent or otherwise dimensionally stable polyester fibers or filaments are combined with hygroscopic materials to form a bicomponent yarn. Other non-absorbent materials, such as rayon, nylon, polyacrylic, and the like, may be used herein. In exemplary aspects, in the finished fabric, second yarn 112 may comprise between 20-30% of the yarn and/or between 22-26% of the yarn.

In exemplary aspects, third yarn 114 may comprise a yarn that is dimensionally stable when exposed to physical stimuli, such as water. In one exemplary aspect, third yarn 114 may comprise a 20 gauge, 100 denier, 144 filament semi-dull, 100% non-absorbent polyester yarn, while in another exemplary aspect, third yarn 114 may comprise a 75 denier, 36 filament semi-dull, 100% non-absorbent polyester yarn or a 75 denier, 72 filament semi-dull, 100% non-absorbent polyester yarn. It is also contemplated herein that cationically dyeable non-absorbent polyester yarn may be used for third yarn 114 alone or in combination with conventional polyester fibers or filaments (i.e., 50% conventional non-absorbent polyester and 50% cationically dyeable polyester yarn). Utilizing different denier/filament ratios may help provide greater or lesser degrees of heat retention. For example, a 100 denier, 144 filament yarn may provide a higher degree of heat retention when formed into a loop than a 75 denier/36 filament yarn. It is contemplated that other non-absorbent fibers or filaments may be used herein, such as rayon, nylon, polyacrylics, and the like. Due to their high abrasion resistance, toughness, elasticity, dimensional stability, and elastic recovery, the use of polyester fibers and/or filaments described herein may be advantageous.

Regarding the construction of knitted structure 100, second yarn 112 forms a plait with first yarn 110, such that second yarn 112 is positioned generally below and/or adjacent to first yarn 110 in the finished fabric or textile. In an exemplary aspect, first yarn 110 and second yarn 112 can be knitted in a single jersey pattern to form a first side or surface 116 of the resulting fabric or textile. Generally, first yarn 110 forms a majority of first surface 116. As is known in the knitting art, a plaited structure comprises loops composed of at least two yarns, each of which is individually fed to the needle hook through its own guide or guide hole to influence its respective position relative to the fabric surface. However, due to factors such as the physical properties of the yarns, the yarn positioned below the facing yarn (in this case, second yarn 112) may occasionally be exposed on the facing surface of the fabric. Thus, when the first yarn 110 is described as forming a majority of the first surface 116 , it is contemplated herein that the majority may include up to 80%, 85%, 90%, 95%, or more, of the first surface 116 .

Next, plating the second yarn 112 with the first yarn 110 may be important to help "lock" or secure the second yarn 112. Given that the second yarn 112 undergoes dimensional changes when exposed to physical stimuli, locking or securing the yarn with the first yarn 110 via the plating and interconnected looping process may be important to at least partially limit some of the dimensional changes of the second yarn 112, so that when the second yarn 112 transitions from, for example, a coiled state to a flat or straight state, a garment incorporating the knit structure 100 does not substantially deform, sag, or droop to a noticeable degree. To avoid excessively locking the second yarn 112 so that its dimensional changes are offset or overly suppressed by the locking or interconnected looping construction, a single knit construction may be desirable. It has been found that such a construction facilitates measurable changes in breathability due to the dimensional changes of the second yarn 112, while still providing sufficient locking so that any garment incorporating the knit constructions described herein maintains its overall shape. Furthermore, the use of a single knit construction may allow for the production of lightweight garments.

Next, third yarn 114 is used to form loops on the second side or second surface 118 of the resulting fabric. Thus, in the finished fabric, first yarn 110 will form the majority of first surface 116 of the fabric, and third yarn 114 will form the opposing second surface 118 of the fabric. In the finished fabric, second yarn 112 will be positioned generally between first yarn 110 and third yarn 114 (and/or between first surface 116 and second surface 118). Other knit configurations are contemplated herein, such as double knit ribbed structures and the like.

Fig. 2 illustrates the exemplary second yarn 112 in curled state and uncoiled state according to aspects of this paper.For example, the second yarn 112 on the left side of the arrow is shown as being in curled state, and wherein curling degree can be considered as the measurement of the waviness in the yarn.When the second yarn 112 is not yet exposed to physical stimulation (for example, water or wet steam), curled state may exist.In an exemplary aspect, yarn 112 can not present curled state, until after yarn 112 experiences dyeing process.For example, during fabric dyeing, the second yarn 112 can be activated when being exposed to predetermined temperature and humidity level and reaching predetermined time period.Due to the shrinkage difference of non-absorbent fiber or silk and absorbent fiber or silk side by side, activation causes the second yarn 112 to be curled into texture state.In exemplary aspect, polycaprolactam or nylon-6 fiber or silk shrink larger degree than cationic dyeable polyester fiber or silk, to produce curled structure.As explained below, the second yarn 112 keeps curled state after activation, until being exposed to stimulation.

The yarn 112 shown to the right of the arrow undergoes a dimensional change when exposed to a physical stimulus (e.g., water). As shown, the second yarn 112 has changed from a coiled state to a substantially non-coiled or flat state. In an exemplary aspect, the change from a coiled state to a non-coiled or flat state can result in an increase in the length of the yarn 112. And as described above, it may be important to limit the dimensional change of the second yarn 112 by forming a plaited yarn with the first yarn 110 to prevent the garment incorporating the second yarn 112 from accidentally sagging or drooping after being exposed to a physical stimulus. Other dimensional changes of the second yarn 112 are contemplated herein, such as an increase or decrease in the diameter of the yarn 112, an increase or decrease in the length of the yarn 112, and the like.

3A and 3B illustrate a second yarn 112 knitted to form a series of interlocking loops according to aspects of the present invention. For illustrative purposes, the second yarn 112 is shown alone, but, as described above with respect to the knit structure 100, the second yarn 112 will form a plait with the first yarn 110, and the third yarn 114 will form a series of loops on the second surface. More specifically, FIG3A illustrates a knit structure 300 incorporating the second yarn 112 in a curled state, and FIG3B illustrates a knit structure 350 with the second yarn 112 in an uncoiled or flat state. In other words, the knit structure 300 appears before the second yarn 112 has been exposed to a physical stimulus (e.g., water), while the knit structure 350 appears after the second yarn 112 has been exposed to the physical stimulus (e.g., water).

By virtue of the interconnected looping configuration, spaces, such as space 310, are formed in the knit structure 300 and the knit structure 350. However, because the yarn 112 is coiled in the knit structure 300, the average area of the spaces 310 in the knit structure 300 is generally smaller than the average area of the spaces 310 in the knit structure 350 where the yarn 112 is straight or uncoiled. Increasing the average area of the spaces 310 when going from a coiled state ( FIG. 3A ) to an uncoiled state ( FIG. 3B ) results in a consequent increase in the overall permeability of the knit structure 350 to, for example, water, light, air, and the like.

For example, as described above, when the second yarn 112 is incorporated into the fabric with the first yarn 110 and the third yarn 114, and when the fabric is exposed to physical stimulation (e.g., water), the fabric can show a positive change in air permeability, as measured using, for example, the standard test method for air permeability of ASTM D737-fabric fabrics. This test method is carried out on both a moist sample and a dry sample. In other words, air permeability is measured on both a moist sample and a dry sample. In exemplary aspects, the test method can be modified by reducing the pressure differential to 20 Pa (relative to 125 Pa in the ASTM D737 test) to prevent the wet fabric from drying, and more closely approximating the air flow and/or the air pressure experienced when, for example, a runner runs.

More specifically, when a fabric comprising second yarn 112 is exposed to a physical stimulus (e.g., water), the fabric can have a positive change in air permeability of 16.0-17.0%, 16.0-16.5%, or 16.1-16.3% as measured before washing. For example, the fabric can exhibit an air permeability between 25.5 ft ³ /min/ft ² and 30.0 ft ³ /min/ft ² when dry and before washing, and between 32.0 ft ³ /min/ft ² and 32.5 ft ³ /min/ft ² when wet and before washing. After washing, the fabric can have a positive change in air permeability of 23.0-39.0%, 26.0-28.0%, or 26.0-27.0%. For example, the fabric may exhibit an air permeability between 17.4 ^ft3 /min/ ^ft2 and 17.9 ^ft3 /min/ ^ft2 when dry and after laundering, and may exhibit an air permeability between 22.4 ^ft3 /min/ ^ft2 and 22.8 ^ft3 /min/ ^ft2 when wet and after laundering.

Next, this is compared to a fabric that does not incorporate the second yarn 112, which can have a negative change in air permeability of 9.0-9.5% before the fabric has been washed and when exposed to a physical stimulus (e.g., water), and can have a negative change in air permeability of 2.0-3.0% after the fabric has been washed and when exposed to a physical stimulus.

A positive change in air permeability generally means that the fabric has become more permeable, while a negative change in air permeability generally means that the fabric has become less permeable. A negative change in air permeability may be due, for example, to water being trapped between the yarns in the knit structure, thereby inhibiting the passage of air through the spaces between the yarns. Furthermore, the difference in the percent change in air permeability before and after washing can be attributed to the shrinkage of the fabric that occurs after washing. For example, when the fabric shrinks, a "tighter" knit structure is created, which may restrict air permeability. As can be seen from the percent change in air permeability of the fabric incorporating the second yarn 112, the percent change in air permeability is higher after washing. This is due to the following: although the air permeability measured after washing and before the stimulus is applied may be smaller due to shrinkage, after the fabric is exposed to the physical stimulus (in this case, water), the air permeability increases to a value close to the value it had before washing, resulting in an overall larger percent change compared to the percent change before washing.

Turning now to FIG. 4 , a first surface 405 of a fabric 400 incorporating a knit structure 100 according to aspects herein is illustrated. As described, first surface 405 is formed by knitting a single jersey pattern using first yarn 110 that forms a plait with second yarn 112. This is indicated in FIG. 4 by reference numeral 410, which illustrates the interlocking pattern of loops. Due to imperfections in the plating process, although first yarn 110 forms a majority (e.g., greater than 80%, greater than 85%, greater than 90%, greater than 95%, or more) of first surface 405 of fabric 400, it is contemplated herein that second yarn 112 may be present on first surface 405. When fabric 400 is incorporated into a garment, first surface 405 may at least partially form the outer-facing surface of the garment, as will be explained in greater detail below.

Fig. 5 illustrates the second surface 505 of the fabric 400 that is combined with the knitted structure 100 according to various aspects of this paper.When fabric 400 is incorporated into clothing, second surface 505 can at least partially form the inward-facing surface of clothing, which will be explained in more depth below.As described, the 3rd yarn 114 is used to form a series of terry loops, and these terry loops are arranged in a group of protrusions 510 separated by space 512.This is shown in the close-up view of Fig. 5, and is represented by reference number 514.In exemplary aspect, protrusion 510 extends in the z direction relative to the surface plane of fabric 400, and each protrusion 510 can terminate in terminal portion 511 (represented by dotted line) to form a node-like structure.This is better shown in the cross-sectional view such as shown in Fig. 6.

FIG6 , which is a cross-sectional view of fabric 400, depicts first surface 405 generally comprising first yarn 110. FIG6 also shows layer 612, which primarily comprises second yarn 112. FIG6 additionally illustrates second surface 505 formed using third yarn 114. As shown, layer 612 formed using second yarn 112 is positioned generally between or between first surface 405 formed using first yarn 110 and second surface 505 formed using third yarn 114.

Continuing with FIG6 , the second surface 505 includes protrusions 510 extending in the z-direction relative to the surface plane of the fabric 400. Each protrusion 510 is separated from an adjacent protrusion 510 by a space 512. Furthermore, each protrusion 510 includes a side portion 622 and a terminal portion 511 located, for example, opposite the first surface 405 and/or the second surface 505. In an exemplary aspect, the side portions 622 can be substantially perpendicular to the surface plane of the fabric 400, such that the terminal portion 511 of the protrusion 510 has a surface area similar to that of the base of the protrusion 510. In another aspect, the side portions 622 can be angled such that the terminal portion 511 of the protrusion 510 has a surface area smaller than that of the base of the protrusion 510. In yet another aspect, the side portions 622 can be angled relative to the surface plane of the fabric 400 such that the terminal portion 511 of the protrusion 510 has a surface area larger than that of the base of the protrusion 510. Any and all aspects and any variations thereof are contemplated to be within the scope herein.

Returning to FIG. 5 , as shown, the protrusions 510 can be positioned adjacent to each other in a tessellation pattern. Utilizing such a pattern can help maximize the number of protrusions 510 per unit area of the fabric 400. Although shown as having a hexagonal shape, it is contemplated herein that the protrusions 510 can have different shapes, such as squares, rectangles, auxetic structures such as triads, triangles, circles, ovals, diamonds, and other known geometric shapes. For example, FIG. 14 illustrates another exemplary shape for protrusions 1400. This shape includes auxetic structures 1410 arranged in a tessellation pattern.

5 , each protrusion 510 can have an approximate diameter (measured from one side of the end portion 511 to the opposite side of the end portion 511) of, for example, between 5 mm and 50 mm, although diameters greater than and less than these ranges are contemplated herein. As stated, each protrusion 510 can be separated from adjacent protrusions 510 by a space 512. The width of the space 512 between adjacent protrusions 510 can be, for example, between 1 mm and 15 mm, although widths greater than and less than these ranges are contemplated herein.

As shown in the close-up view of FIG. 5 , the protrusions 510, including their distal ends 511, are formed from the loops of the knitted structure 100. Using a loop structure to form the protrusions 510 helps increase the surface area of the protrusions 510, which in turn can be used to trap air when the fabric 400 is incorporated into a garment and the garment is worn by the wearer. In an optional aspect, the distal ends 511 of the protrusions 510 can be brushed to further increase the surface area and impart increased softness or warmth to the protrusions 510. Thus, the thermal insulation provided by the protrusions 510 can be primarily attributed to the size and/or surface area of the protrusions 510, the brushed distal ends, the density of the protrusions 510, and the like. In one exemplary aspect, the fabric 400 and its protrusions 510 can have a thermal resistance of 0.05 RCT or less. RCT is a measure of thermal resistance and provides an indication of the effectiveness of a fabric in providing warmth or heat retention to the wearer. In one exemplary aspect, thermal resistance can be measured using the test method ISO 11092 Fabrics - Physiological effects - Measurement of thermal and water vapor resistance under steady-state conditions (Sweat Protection - Hot Plate Test). In one exemplary aspect, the RCT value of fabric 400 can decrease when the fabric is exposed to a physical stimulus such as water. This may be due, for example, to increased permeability of fabric 400 after exposure to water. Any and all aspects and any variations thereof are contemplated as being within the scope of this disclosure.

In an exemplary aspect, the spaces 512 between adjacent protrusions 510 can be used as hinge points or bending points, for example, allowing adjacent protrusions 510 to bend toward or away from each other when the fabric 400 is manipulated, thereby increasing the softness and/or drape of the fabric 400. The softness and/or drape of the fabric 400 can also be increased by using a single knit construction. In addition, when the fabric 400 is incorporated into a garment and the garment is worn, the spaces 512 can serve as conduits for air movement. In other words, when incorporated into a garment, air can travel through the spaces 512, thereby providing a certain degree of ventilation for the fabric 400. Therefore, the combined use of the protrusions 510 and the spaces 512 between the protrusions 510 helps create a flexible fabric that provides insulation to the wearer when the garment is worn, while still achieving a certain degree of ventilation to improve the wearer's comfort.

As described, third yarn 114 used to form second surface 505 of fabric 400 can include non-absorbent polyester yarn. In an exemplary aspect, second surface 505 of fabric 400 formed using third yarn 114 can have moisture management properties (i.e., the ability of the fabric to move moisture from one surface to an opposite surface through, for example, capillary action, denier differences, and the like). For example, moisture and/or perspiration can move from the wearer's body surface between yarns 114 forming protrusions 510 and to second yarn 112. Once moisture and/or perspiration has reached second yarn 112, it can cause the yarn 112 to change in dimension, which results in increased breathability of fabric 400, as described above with reference to Figures 3A and 3B.

In exemplary aspects, fabric 400 can be incorporated into clothing. Exemplary clothing 700 is shown in Figures 7 and 8, and Figures 7 and 8 respectively depict the front view and the back view of clothing 700 according to aspects of this article. Although shown as clothing for the upper body of the wearer, it is contemplated herein that clothing 700 can be in the form of clothing for the lower body of the wearer (e.g., pants, shorts, leggings, leggings and the like), or clothing 700 can take the form of socks, leggings or other types of protective equipment, hats and the like. Any aspect and all aspects and any variations thereof are contemplated as being within the scope of this article. In addition, although the clothing 700 in Figures 7 and 8 is shown as the form of a jacket, it is contemplated herein that clothing 700 can be in the form of a shirt (pullover, hoodie, sweatshirt and the like), a coat, and/or it can include a lining layer suitable for wearing below the outer shell layer or can include an outer shell layer suitable for wearing on the lining layer. Similarly, although not shown, clothing 700 can include an optional hood part. Any and all aspects and any variations thereof are contemplated to be within the scope herein.

7 , the regionalized garment 700 includes at least a front portion 710 adapted to be positioned adjacent to the wearer's front torso region when the garment 700 is worn, and a first sleeve portion 712 and a second sleeve portion 714 adapted to be positioned adjacent to the wearer's arms when the garment 700 is worn. As shown in FIG7 and FIG8 , the garment 700 also includes side portions 716, indicated by dashed lines, configured to be positioned adjacent to the wearer's side regions when the garment 700 is worn. In one exemplary aspect, the side portions 716 can extend from the lower edges of the sleeve openings for the sleeve portions 712 and the sleeve portions 714 to near or at the waist opening of the garment 700, however, it is contemplated herein that the side portions 716 can extend from an area proximate the sleeve openings of the sleeve portions 712 and the sleeve portions 714 to an area proximate the waist opening of the garment 700. Any and all aspects and any variations thereof are contemplated as being within the scope of this disclosure. Garment 700 is shown with an optional releasable closure mechanism 715 (e.g., a zipper) that can be used to open and close garment 700 for donning and doffing. When in shirt form, releasable closure mechanism 715 may not be used.

With respect to Figure 8, garment 700 also includes a rear portion 810 that is adapted to be positioned adjacent to the wearer's rear torso region when garment 700 is worn. When garment 700 is worn, a central rear portion 812 (represented by a dotted line) can extend along a region adjacent to the wearer's spine. For example, central rear portion 812 can extend from the neck opening of garment 700 to the waist opening of garment 700, although it is contemplated herein that central rear portion 812 can extend from a region proximate the neck opening of garment 700 to a region proximate the waist opening of garment 700. Any and all aspects and any variations thereof are contemplated to be within the scope of this article.

In an exemplary aspect, the front portion 710, the back portion 810, and/or the sleeve portions 712 and the sleeve portions 714 can be formed from separate pieces that are attached together to form the garment 700. In other aspects, the front portion 710, the back portion 810, and/or the sleeve portions 712 and the sleeve portions 714 can be formed from seamless construction, for example, using a flat knitting process, a circular knitting process, and the like. Next, the side portions 716 can comprise an integral extension of the front portion 710 and/or the back portion 810, or the side portions 716 can comprise a separate piece between the front portion 710 and the back portion 810. Similarly, the center back portion 812 can comprise an integral extension of the back portion 810, or the center back portion 812 can comprise a separate piece inserted into the back portion 810. Any and all aspects and any variations thereof are contemplated as being within the scope of this document.

In an exemplary aspect, some or all of garment 700 can be formed using fabric 400. In one example, only side portions 716 and center back portion 812 can be formed from fabric 400, such that the outward-facing surfaces of these portions 716 and 812 can comprise first surface 405 of fabric 400. In another example, the entirety of garment 700 (including or excluding sleeve portions 712 and sleeve portions 714) can be formed from fabric 400, such that the outward-facing surface of garment 700 comprises first surface 405 of fabric 400. Other configurations are also contemplated herein. For example, different areas of front portion 710 can be formed from fabric 400, such that the outward-facing surfaces of these areas can comprise first surface 405 of fabric 400. Any and all aspects and any variations thereof are contemplated as being within the scope of this document.

It is contemplated herein that an additional backing layer may optionally be positioned on some or all of the outward-facing surfaces of garment 700. In this regard, the backing layer may be attached to the outward-facing surface of garment 700 using, for example, welding, adhesives, thermal bonding, stitching, and the like. In some aspects, the backing layer may be selectively applied to the outward-facing surface of garment 700 using, for example, an adhesive applied in a dot pattern, spot welding, and the like to increase the permeability and/or breathability of garment 700. In aspects where the backing layer comprises a separate fabric attached to the outward-facing surface of garment 700 to form a composite fabric, the backing layer may comprise, for example, a double-faced jersey or a spacer mesh. Such materials may help provide structure to garment 700 while still providing breathability and/or permeability characteristics. In exemplary aspects, various functional finishes, such as durable water repellents, may be applied to the backing layer to help make the resulting garment 700 substantially impermeable. Any and all aspects and any variations thereof are contemplated as being within the scope of this invention.

9 , a front view of a garment 700 is provided, according to aspects of the present invention, wherein the garment 700 is in an open position so that the inner or inward-facing surface of the garment 700 is shown. The fabric 400 is shown as being incorporated into the garment 700 at least at the side portions 716 and the center back portion 812 of the garment 700. The selection of these areas can be based on, for example, a sweat or heat map of the human body, since sweat generated by the wearer can be used to trigger, for example, a dimensional change in the second yarn 112. However, as described above, it is further contemplated herein that the fabric 400 can be incorporated into other areas of the garment 700, such as the areas indicated by reference numerals 910 , 912 , 914 , and/or 916 , or that the fabric 400 can constitute the entirety of the garment 700, including or excluding the sleeve portions 712 and the sleeve portions 714.

As shown in FIG9 , the projections 510 of the fabric 400 extend inwardly so that when the garment 700 is worn, the projections 510 face the surface of the wearer's body. Although the projections 510 are shown as being substantially equal in diameter, it is contemplated herein that the projections 510 may comprise different diameters. Due to the construction of the fabric 400, the projections 510 can be used to provide thermal insulation for the wearer. In other words, the loops of the projections 510 can help capture warm air generated by the wearer and keep it in contact with the wearer's body. This is particularly useful when the wearer is resting or exercising lightly.

Next, when the wearer begins to exercise and produces sweat, it may be important to dissipate some of the heat generated by the wearer to keep the wearer within the optimal temperature range. Due to the construction of fabric 400, the loops can help draw sweat generated by the wearer to the second yarn 112 located adjacent to the second surface 505 of fabric 400. Once exposed to sweat, second yarn 112 can undergo a dimensional change, for example, changing from a coiled state to an uncoiled or flat state. As explained with respect to Figures 3A and 3B, this change causes the size of the opening formed by the loops of first yarn 110 and second yarn 112 to increase, resulting in increased permeability. The increase in permeability can help cool the wearer by allowing air from the surrounding environment to collect in the article of clothing 700 and by creating a path through which moisture vapor and/or heat generated by the wearer can escape. Once the wearer has stopped sweating, second yarn 112 can be converted back to a coiled state, causing the permeability of fabric 400 to decrease, thereby retaining the wearer's body heat.

Regarding regions 910, 912, 914, and 916 in FIG. 9 , these regions generally correspond to areas of the wearer that generate less heat and/or less sweat when garment 700 is worn. It is contemplated herein that a fabric having a construction somewhat similar to fabric 400 but lacking second yarn 112 could be used to form regions 910, 912, 914, and 916. In other words, the fabric would have an outward-facing surface similar to surface 405 of fabric and would further include protrusions, such as protrusion 510 of fabric 400, but would not include adaptive second yarn 112. Thus, this fabric could be used to provide thermal insulation characteristics, but would not experience increased breathability when the wearer begins to sweat. Thus, by utilizing a combination of fabric 400 in portions 716 and 812 and the fabrics described above in regions 910, 912, 914, and 916, the wearer of garment 700 can maintain an optimal temperature range, for example, during exercise and rest. It is also contemplated herein that other fabrics may be used to form regions 910, 912, 914, and 916. For example, a fabric that does not have the protrusions shown in Figure 5 may be used in these regions. Any and all aspects and any variations thereof are contemplated as being within the scope of this disclosure.

10 and 11 depict front and rear perspective views, respectively, of an outward-facing surface of another exemplary garment 1000 according to aspects herein. Many of the general discussions regarding garment 700 also apply to garment 1000. Similar to garment 700, garment 1000 includes at least a torso portion 1010 having a front side 1012 (shown in FIG. 10 ) and a rear side 1110 (shown in FIG. 11 ). Article of apparel 700 is in the form of a pullover, but other configurations are contemplated herein, such as jackets, vests, pants, shorts, hats, socks, and the like.

10 , an area designated by reference numeral 1014 and illustrated using dashed lines is illustrated as extending along a central portion of a front side 1012 of torso portion 1010. In an exemplary aspect, area 1014 can extend from an area proximate the neck opening of garment 1000 (i.e., within 5 cm to 15 cm of the neck opening) to an area approximately 5 cm to 40 cm from the bottom edge of garment 1000. In an exemplary aspect, an area designated by reference numeral 1112 and illustrated using dashed lines is illustrated as extending along a central portion of a back side 1110 of torso portion 1010. In an exemplary aspect, area 1112 can extend from an area proximate the neck opening of garment 1000 (i.e., within 5 cm to 15 cm of the neck opening) to an area approximately 5 cm to 30 cm from the bottom edge of garment 1000.

In an exemplary aspect, regions 1014 and 1112 can be formed from fabric 400. When garment 1000 is worn, regions 1014 and 1112 generally correspond to areas of the wearer's body that experience significant perspiration. Thus, using fabric 400 to form these regions increases the likelihood that second yarn 112 will change dimensionally and cause fabric 400 to experience increased breathability. Similar to garment 700, other regions of garment 1000 can be formed from fabric that does not include adaptive second yarn 112. Any and all aspects and any variations thereof are contemplated as being within the scope of this disclosure.

Figures 12 and 13 illustrate front and rear perspective views of another exemplary garment 1200 according to aspects of this invention, respectively. Similarly, many of the general discussions about garment 700 also apply to garment 1200. Garment 1200 incorporates fabric 400 in additional areas, in addition to the illustrated areas of garment 1000, as shown by the dashed lines. When garment 1200 is worn, this additional area may generally correspond to a moderately sweat-producing area of the wearer. For example, similar to garment 1000, in addition to being incorporated into the center front side 1211 and center back side 1311 of torso portion 1210, fabric 400 may also be incorporated along shoulder area 1214 of torso portion 1210 and may extend from shoulder area 1214 to center front side 1211 and center back side 1311 of torso portion 1210. It may also be incorporated along the outer side of the back side of torso portion 1210 in an area near the lower edge of garment 1200 (i.e., in an area approximately 5 cm to 40 cm from the lower edge of garment 1200), as indicated by reference numeral 1312. Other areas of garment 1200 may be formed from fabric that does not include adaptive yarn 112. Any and all aspects and any variations thereof are contemplated as being within the scope of this disclosure.

The foregoing description of examples of the present invention has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention. Individual elements or features of a particular example are generally not limited to that particular example, but, where applicable, are interchangeable and can be used in a selected example, even if not explicitly shown or described.

Claims (20)

1. A garment, comprising A first garment portion is formed from a first material having a first surface and a second surface, the first material being formed using at least a first yarn, a second yarn, and a third yarn. The first yarn is dimensionally stable when exposed to moisture, and the second yarn changes from a crimped state to an uncrimped or flat state when exposed to the moisture. The second yarn forms a lining with the first yarn such that the first yarn substantially forms the first surface of the first material, and the second yarn is substantially positioned below the first yarn. The third yarn forms the second surface of the first material, and the third yarn forms a plurality of protrusions extending from the second surface, each of the plurality of protrusions having an end portion positioned relative to the first material. Wherein, the first garment portion exhibits first breathability when not exposed to the moisture, and wherein the first garment portion exhibits second breathability when exposed to the moisture, the first breathability being less than the second breathability. 2. The garment of claim 1, wherein the first material comprises a knitted material, and wherein the first surface of the first material constitutes the outward-facing surface of the garment, and wherein the second surface of the first material constitutes the inward-facing surface of the garment. 3. The garment according to claim 2, wherein the first yarn comprises 50% conventional polyester fiber or filament and 50% cationic dyeable polyester fiber or filament. 4. The garment according to claim 3, wherein the second yarn is a bicomponent yarn formed of nylon-6 fiber or filament and cationic dyeable polyester fiber or filament. 5. The garment according to claim 4, wherein the second yarn comprises 50% nylon-6 fiber or filament and 50% cationic dyeable polyester fiber or filament. 6. The garment according to claim 2, wherein the third yarn is dimensionally stable when exposed to the moisture. 7. The garment according to claim 6, wherein the third yarn comprises 100% polyester fiber or filament. 8. The garment according to claim 2, wherein the plurality of protrusions are positioned adjacent to each other in an inlay pattern. 9. A knitted fabric, comprising: A first surface and an opposite second surface; The first yarn is dimensionally stable when exposed to water; The second yarn, which exhibits a dimensional change upon absorbing water, forms a filler yarn with the first yarn, such that the first yarn substantially forms the first surface of the knitted fabric, and the second yarn is substantially positioned below the first yarn; and A third yarn, which forms the second surface of the knitted fabric, is mechanically manipulated to form a plurality of protrusions extending from the second surface, each of the plurality of protrusions having an end portion positioned opposite to the second surface. The knitted fabric exhibits a first breathability when not exposed to water and a second breathability when exposed to water, wherein the first breathability is less than the second breathability. 10. The knitted fabric of claim 9, wherein the knitted fabric comprises a single-knit plain knit fabric, and wherein the plurality of protrusions comprises French loops. 11. The knitted fabric according to claim 9, wherein the third yarn is dimensionally stable when exposed to water. 12. The knitted fabric according to claim 9, wherein the second yarn constitutes 20% to 30% of the knitted fabric. 13. The knitted fabric according to claim 11, wherein the third yarn comprises 100% polyester fiber or filament. 14. The knitted fabric of claim 9, wherein the plurality of protrusions are positioned adjacent to each other in an inlay pattern. 15. The knitted fabric of claim 14, wherein the side portions of the plurality of protrusions are substantially perpendicular to the surface plane of the second surface of the knitted fabric. 16. A garment comprising a torso region having at least a front region, a rear region, a first arm opening and a second arm opening, a first side region and a second side region, the first side region extending from near the first arm opening to near a waist opening of the garment, the second side region extending from near the second arm opening to near the waist opening of the garment; wherein at least a first portion of the garment is formed of a first material having a first surface and a second surface, the first material comprising at least a first yarn, a second yarn and a third yarn, the first yarn being dimensionally stable upon exposure to moisture, the second yarn changing from a crimped state to an uncrimped or flat state upon exposure to the moisture, the second yarn forming a lining with the first yarn such that the first yarn substantially forms the first surface of the first material and the second yarn is substantially positioned below the first yarn, the third yarn forming the second surface of the first material, the third yarn forming a plurality of protrusions extending from the second surface, each of the plurality of protrusions having an end portion positioned relative to the first material. Wherein, the first material exhibits a first breathability when not exposed to the moisture, and wherein the first material exhibits a second breathability when exposed to the moisture, the second breathability being greater than the first breathability. 17. The garment of claim 16, wherein the first surface of the first material constitutes the outward-facing surface of the first material, and wherein the second surface of the first material constitutes the inward-facing surface of the first material. 18. The garment of claim 17, wherein the first portion of the garment is positioned at least in the vertical direction along the central portion of the rear region of the garment. 19. The garment of claim 16, wherein the third yarn is dimensionally stable when exposed to the moisture. 20. The garment of claim 19, wherein the second breathability is at least 25% greater than the first breathability.