3-D fabric knitted stretch spacer material having molded domed patterns and method of making

Abstract

A fabric having a face surface and a back surface forming a fabric plane, wherein the fabric is further processed to produce spaced apart, repeated patterned domes extending out of the fabric plane, the domes forming channels therebetween, producing a molded formed 3-D fabric for evaporative cooling and/or insulation as well as comfort, stretch, compression resistance, decreased weight, and improved drape, softness, and/or conformability, depending upon the yarn component and fabric properties.

1 . A three-dimensional fabric for insulating and/or cooling comprising 
 a knitted spacer material, the material further comprising:    a face surface;    a back surface in spaced apart relation to the face surface; and    a body portion constructed therebetween forming a unitary, integrally constructed material within a first material plane;    wherein material is formed into patterned domed shapes projecting out of the first material plane.    
   
   
       2 . The three-dimensional fabric of  claim 1 , wherein the domed shapes are provided in a predetermined, repeatable pattern.  
   
   
       3 . The three-dimensional fabric of  claim 1 , wherein the domed shapes are substantially uniform in shape.  
   
   
       4 . The three-dimensional fabric of  claim 1 , wherein the domed shapes vary in size and/or shape.  
   
   
       5 . The three-dimensional fabric of  claim 1 , wherein the domed shapes are circular or oval in shape.  
   
   
       6 . The three-dimensional fabric of  claim 1 , wherein the domed shapes are multi-sided in shape.  
   
   
       7 . The three-dimensional fabric of  claim 6 , wherein the multi-sided domed shapes have rounded edges.  
   
   
       8 . The three-dimensional fabric of  claim 6 , wherein the multi-sided domed shapes have sharp edges.  
   
   
       9 . The three-dimensional fabric of  claim 8 , wherein the said multi-sided domed shapes have cross-sectional shapes selected from the group consisting of round, triangular, square, pentagonal , hexagonal, octagonal.  
   
   
       10 . The three-dimensional fabric of  claim 1 , wherein the domed shapes have non-symmetrical shapes.  
   
   
       11 . The three-dimensional fabric of  claim 1 , wherein the domed shapes produce channels therebetween.  
   
   
       12 . The three-dimensional fabric of  claim 1 , wherein the domed shapes protrude beyond the base fabric plane to a predetermined height and angle.  
   
   
       13 . The three-dimensional fabric of  claim 12 , wherein the height of the domes is at least equivalent to or greater than the thickness of the said fabric.  
   
   
       14 . The three-dimensional fabric of  claim 12 , wherein the height of the domes range between 2-20 times the thickness of the said fabric.  
   
   
       15 . The three-dimensional fabric of  claim 1 , wherein the fabric is formed of three yarn systems: a first yarn system constituting the said face surface; a second yarn system constituting the said back surface; and a third yarn system constituting the said body portion.  
   
   
       16 . The three-dimensional fabric of  claim 15 , wherein at least one of the said three yarn systems includes an elastomeric yarn component.  
   
   
       17 . The three-dimensional fabric of  claim 15 , wherein at least one of the said three yarn systems includes a monofilament yarn component.  
   
   
       18 . The three-dimensional fabric of  claim 15 , wherein at least one of the said three yarn systems includes a multifilament yarn component.  
   
   
       19 . The three-dimensional fabric of  claim 15 , wherein at least one of the said three yarn systems includes a high strength yarn component.  
   
   
       20 . The three-dimensional fabric of  claim 1 , wherein the knitted spacer material includes a monofilament core.  
   
   
       21 . The three-dimensional fabric of  claim 1 , wherein the fabric further comprises a secondary component, with said secondary component being applied to the fabric as a lamination.  
   
   
       22 . The three-dimensional fabric of  claim 1 , wherein the fabric further comprises a secondary component, with said secondary component being applied to the fabric as a coating.  
   
   
       23 . The three-dimensional fabric of  claim 22 , wherein said secondary component includes at least one moisture barrier.  
   
   
       24 . The three-dimensional fabric of  claim 22 , wherein said secondary component includes at least one phase change material.  
   
   
       25 . The three-dimensional fabric of  claim 22 , wherein said secondary component includes at least one antimicrobial agent.  
   
   
       26 . The three-dimensional fabric of  claim 1 , wherein the fabric further comprises a secondary component, with said secondary component being applied to the fabric as an infusion.  
   
   
       27 . The three-dimensional fabric of  claim 22 , wherein said secondary component includes at least one medication.  
   
   
       28 . The three-dimensional fabric of  claim 1 , wherein a sandwich-like material having a first side; and a spaced apart, parallel second side is used as a base fabric, with said base fabric being processed to produce the said three-dimensional fabric having plurality of domed shapes.  
   
   
       29 . The three-dimensional fabric of  claim 28 , wherein the said sandwich-like material has a thickness ranging between about 2 mm and about 10 mm prior to further processing to create the three dimensional fabric.  
   
   
       30 . The three-dimensional fabric of  claim 28 , wherein said processing of the base fabric is provided via molding.  
   
   
       31 . The three-dimensional fabric of  claim 1 , wherein said fabric is used as a liner for protective garments and/or equipment.  
   
   
       32 . The three-dimensional fabric of  claim 1 , wherein said fabric is used as a liner for a garment.  
   
   
       33 . The three-dimensional fabric of  claim 1 , wherein said fabric is used as a liner for at least one part of a garment.  
   
   
       34 . The three-dimensional fabric of  claim 1 , wherein the fabric is used as a carrier for a secondary component including at least one medication.  
   
   
       35 . The three-dimensional fabric of  claim 1 , wherein at least one wicking treatment is topically applied to the fabric or impregnated in at least one of the yarn components.  
   
   
       36 . A three-dimensional fabric, having a plurality of domed shapes, comprising monofilament yarn components interconnected to form a base fabric, which is thereafter formed into a 3-D dome-channeled material for use as a garment or portion of a garment for providing ventilation under protective equipment and/or clothing.  
   
   
       37 . A method of manufacturing a three-dimensional fabric, formed from a knitted spacer material, and having a plurality of domed shapes, including the steps of: 
 providing at least two yarn systems for interconnecting via a knitting pattern, wherein at least one of the at least two yarn systems includes a stretch yarn component and at least one of the at least two yarn systems includes a monofilament component;    knitting the stretch yarn component according to a predetermined pattern;    providing corresponding male and female mating mold components for forming three dimensional domes in predetermined, repeating patterns in the fabric;    inserting the fabric between the molds;    closing molds together with the fabric there-between to produce dome shapes protruding from the fabric plane;    providing adequate, predetermined pressure and/or temperature for setting the dome shapes in the fabric; and    removing the fabric from the molds after a predetermined dwell time.    
   
   
       38 . The method of  claim 37 , wherein the said predetermined dwell time ranges preferably between about 15 seconds and about 10 minutes, and more preferably between about 1 minute and about 5 minutes.  
   
   
       39 . The method of  claim 37 , further including additional steps by which the manufactured three dimensional fabric is cut and sewed to form a garment, or at least a portion of a garment.  
   
   
       40 . The method of  claim 37 , further including additional steps by which a secondary component being applied to the fabric as a lamination or a coating.