Double knit fabric

Abstract

A double-knit fabric containing a first knit layer, a second knit layer, and a plurality of stuffer yarns. The stuffer yarns are located between the first knit layer and the second knit layer. The double-knit fabric contains a plurality of anchored regions and a plurality of detached regions. In the anchored regions, the first and second fabric layers are knitted together and in the detached regions the first and second fabric layers are unattached. The average peak distance between the first and second fabric layers in the detached regions is at least about 3 mm and the double-knit fabric has between about 10 and 30 detached regions per square inch. The anchored regions contain at least two knit stitches in at least one direction and the anchored regions have a width of at least about 1 mm.

What is claimed is: 
     
         1 . A double-knit fabric having an upper surface and a lower surface and having a warp and weft direction, wherein the weft direction is perpendicular to the warp direction, wherein the double-knit fabric comprises:
 a first knit layer comprising a plurality of first yarns, wherein the first knit layer forms the upper surface of the double-knit fabric;   a second knit layer comprising a plurality of second yarns, wherein the second knit layer forms the lower surface of the double-knit fabric; and,   a plurality of stuffer yarns, wherein the stuffer yarns are located between the first knit layer and the second knit layer;   wherein the double-knit fabric comprises a plurality of anchored regions and a plurality of detached regions, wherein the plurality of detached regions are interspersed between the anchored regions, wherein in the anchored regions the first yarns from the first fabric layer and the second yarns from the second fabric layer are knitted together, and wherein in the detached regions the first fabric layer and second fabric layer are unattached;   wherein the first knit layer and the second knit layer are integrated within the anchored regions at least one method selected from the group consisting of interlacing first yarns of the first knit layer among the second yarns of the second knit layer, interlacing the second yarns of the second layer among the first yarns of the first knit layer, and interlacing a plurality of third yarns among the first yarns of the first knit layer and the second yarns of the second knit layer;   wherein the average peak distance between the first fabric layer and the second fabric layer in the detached regions is at least about 3 mm, wherein the double-knit fabric has between about 10 and 30 detached regions per square inch, wherein the anchored regions comprise at least two knit stitches in at least one of the warp and weft directions, wherein the anchored regions have a width of at least about 1 mm in both the warp and weft directions.   
     
     
         2 . The double-knit fabric of  claim 1 , wherein the average peak distance between the first fabric layer and the second fabric layer in the detached regions is at least about 3.5 mm. 
     
     
         3 . The double-knit fabric of  claim 1 , wherein the double-knit fabric has between about 15 and 25 detached regions per square inch. 
     
     
         4 . The double-knit fabric of  claim 1 , wherein the anchored regions comprise at least three knit stitches in at least one of the warp and weft directions. 
     
     
         5 . The double-knit fabric of  claim 1 , wherein the anchored regions have a width of at least about 1.8 mm in both the warp and weft directions. 
     
     
         6 . The double-knit fabric of  claim 1 , wherein the double-knit fabric has a clo value measured by test ASTM F1868 is at least about 0.2. 
     
     
         7 . The double-knit fabric of  claim 1 , wherein the double-knit fabric has a clo value measured by test ASTM F1868 is at least about 0.3. 
     
     
         8 . The double-knit fabric of  claim 1 , wherein the double-knit fabric has a clo value measured by test ASTM F1868 is at least about 0.4. 
     
     
         9 . The double-knit fabric of  claim 1 , wherein the double-knit fabric has an air permeability of at least about 150 CFM. 
     
     
         10 . The double-knit fabric of  claim 1 , wherein the double-knit fabric has an air permeability of at least about 200 CFM. 
     
     
         11 . The double-knit fabric of  claim 1 , wherein the detached areas have at least one dimension within the plane of the double-knit knit of at least about 3 mm. 
     
     
         12 . The double-knit fabric of  claim 1 , wherein the stuffer yarns run generally parallel to each other. 
     
     
         13 . The double-knit fabric of  claim 1 , wherein the first layer and the second layer are integrated through combined portions formed by interlacing first yarns of the first knit layer among the second yarns of the second knit layer. 
     
     
         14 . The double-knit fabric of  claim 1 , wherein the first yarns are polyester yarns. 
     
     
         15 . The double-knit fabric of  claim 1 , wherein the double-knit fabric consists essentially of polyester, defined as being at least 98% by weight polyester. 
     
     
         16 . The double-knit fabric of  claim 1 , wherein the detached regions have an irregular oval shape in a repeating grid pattern. 
     
     
         17 . The double-knit fabric of  claim 1 , wherein the upper surface of the double-knit fabric comprises a topography formed from the anchored and detached regions, wherein the topography has an average entrained air height of between about 0.3 mm and 25 mm. 
     
     
         18 . A garment comprising the double-knit fabric of  claim 1 . 
     
     
         19 . The garment of  claim 18 , wherein the garment is selected from the group consisting of a jacket, pants, hat, and shirts.