The knitted textiles include a knitted structure including a plurality of hollow yarns. Each hollow yarn includes a yarn body and defines a yarn hole extending through the yarn body to allow expansion of the yarn body upon inflation of each hollow yarn through the yarn hole. The knitted structure is configured to transition from an unexpanded state to an expanded state in response to the inflation of the hollow yarns through the yarn hole. The knitted structure has a first porosity in the unexpanded state, and the knitted structure has a second porosity in the expanded state. The second porosity is less than the first porosity such that a visibility through the knitted structure is greater when the knitted structure is in the unexpanded state than when the knitted structure is in the expanded state.

INTRODUCTION

The present disclosure generally relates to multi-functional knitted textiles. For instance, the present disclosure describes variable porosity knitted textiles including inflatable tubular yarns.

Knitted textiles are used for many purposes. For instance, knitted textiles can be used as a covering for a vehicle seat. Also, knitted textiles can be used for vehicle trims.

SUMMARY

The present disclosure relates to multi-functional knitted textiles. In some embodiments, the knitted textiles include a knitted structure including a plurality of hollow yarns. Each of the plurality of hollow yarns includes a yarn body. Each of the plurality of hollow yarns defines a yarn hole extending through the yarn body to allow expansion of the yarn body upon inflation of each of the plurality of hollow yarns through the yarn hole. The yarn body can also collapse/contract upon drawing a vacuum or negative pressure. The knitted structure is configured to transition from an unexpanded state to an expanded state in response to the inflation of the hollow yarns through the yarn hole. The knitted structure has a first porosity in the unexpanded state, and the knitted structure has a second porosity in the expanded state. The second porosity is less than the first porosity such that a visibility through the knitted structure is greater when the knitted structure is in the unexpanded state than when the knitted structure is in the expanded state. The hollow yarns may be tubular yarns. The breathability through the knitted structure is greater when the knitted structure is in the unexpanded state than when the knitted structure is in the expanded state. Each of the plurality of hollow yarns may include an elastomer. The knitted structure defines a plurality of pores between the plurality of hollow yarns. The plurality of pores have a first average pore size when the knitted structure is in the unexpanded state. The plurality of pores have a second average pore size when the knitted structure is in the expanded state. The second average pore size is less than the first average pore size such that a thermal conductivity of the knitted structure is less when the knitted structure is in the expanded state than when the knitted structure is in the unexpanded state. Each of the plurality of hollow yarns may include a plurality of dopant particles. Each of the plurality of dopant particles may be thermally conductive particles. The dopant particles are closer to each other when the knitted structure is in the unexpanded state than when the knitted structure is in the expanded state such that an electrical conductivity of the knitted structure is greater when the knitted structure is in the unexpanded state than when the knitted structure is in the expanded state.

In some embodiments, the knitted textile includes a knitted structure including a plurality of hollow yarns. Each of the plurality of hollow yarns includes a yarn body. Each of the plurality of hollow yarns defines a yarn hole extending through the yarn body to allow fluid flow through the yarn body in order to control a temperature of the knitted structure. Each of the hollow yarns defines an inner yarn surface and an outer yarn surface. The outer yarn surface is opposite the inner yarn surface. The inner yarn surface defines the yarn hole. Each of the plurality of hollow yarn may include a plurality of thermally-conductive particles embedded in each of the hollow yarns which matrix is less thermally conductive. The thermally-conductive particles are embedded between the inner yarn surface and the outer yarn surface in order to minimize the thermal conductivity of each of the hollow yarns when expanded/inflated and maximize thermal conductivity when relaxed/deflated/vacuumed. Each of the hollow yarns includes a circumferential wall. The circumferential wall defines an inner yarn surface and an outer yarn surface. The outer yarn surface is opposite the inner yarn surface. The inner yarn surface defines the yarn hole. The yarn hole is a longitudinal hole. The hollow yarns may be porous tubular yarns that defines a plurality of thru-holes extending from the inner yarn surface to the outer yarn surface to allow a fluid flowing through the longitudinal hole to exit the yarn body through the thru-holes, thereby allowing the fluid to exit the yarn body through the circumferential wall. The knitted textile may include a plurality of transparent yarns to control observable angles through the knitted structure. The knitted structure may include a plurality of translucent yarns to control observable angles through the knitted structure. The knitted structure may include optically-active yarns to control observable angles through the knitted structure.

In some embodiments, the knitted textile includes a first knitted fabric layer, a second knitted fabric layer, and a knitted spacer fabric interconnecting the first knitted fabric layer and the second knitted fabric layer. The knitted spacer fabric includes a plurality of moisture-wicking yarns. The plurality of moisture-wicking yarns interconnect the first knitted fabric layer and the second knitted fabric layer to transport moisture from the first knitted fabric layer toward the second knitted fabric layer. The second knitted fabric layer includes a plurality of absorbent yarns to collect the moisture transported from the first knitted fabric layer to the second knitted fabric layer through the plurality of moisture-wicking yarns. The second knitted fabric layer may include a plurality of anti-microbial yarns to kill bacteria. The second knitted fabric layer may include a plurality of yarn loops in order to maximize a speed of moisture evaporation. Each of the plurality of absorbent yarns includes a yarn body and a yarn hole extending through the yarn body to allow air to flow through the yarn body. Each of the plurality of absorbent yarn includes a hygroscopic material to absorb moisture in response to the air flowing through the yarn hole of each of the plurality of absorbent yarns. Each of the plurality of absorbent yarns includes a yarn body and a yarn hole extending through the yarn body. The yarn body includes a hygroscopic material configured to absorb moisture. Each of the plurality of absorbent yarns includes a core extending through the yarn hole. The core includes a hydrophilic material to aid in a capillary action for moisture transport. Instead of the core, a hydrophilic coating is applied on the interior of the yarn body.

DETAILED DESCRIPTION

Referring to the drawings, wherein like reference numbers correspond to like or similar components throughout the several figures, and beginning withFIGS. 1-4, a knitted textile10includes a knitted structure12including a plurality of hollow yarns14. The hollow yarns14may be, for example, tubular yarns that can be inflated to change the porosity and/or density of the knitted structure12. Each of the hollow yarns14includes a yarn body16and defines the yarn hole18extending through the yarn body16to allow expansion of the yarn body16upon inflation of the hollow yarn14through the yarn hole18. Accordingly, the knitted structure12is configured to transition from an unexpanded state (e.g., deflated state as shown inFIG. 1) to an expanded state (e.g., inflated state as shown inFIG. 2) in response to the inflation of the hollow yarns14through the yarn hole18. When the hollow yarns14are in the unexpanded (e.g., deflated) state, the knitted structure12is relatively open and porous, wherein, when the hollow yarns14are in the expanded (e.g., inflated) state, the knitted structure12fills the gaps between the hollow yarns14. In other words, when the knitted structure12transitions from the unexpanded state to the expanded state, the hollow yarns14thicken. The knitted structure12has a first porosity and/or density in the unexpanded state (FIG. 1) and a second porosity and/or density in the expanded state (FIG. 2). The second porosity (FIG. 2) of the knitted structure12is less than the first porosity (FIG. 1), and, as a consequence, the visibility through the knitted structure12is greater when the knitted structure12is in the unexpanded state (FIG. 1) than when the knitted structure12is in the expanded state (FIG. 2). Likewise, the second density (FIG. 2) of the knitted structure12is greater than the first density (FIG. 1) of the knitted structure12and, as a consequence, the visibility through the knitted structure12is greater when the knitted structure12is in the unexpanded state (FIG. 1) than when the knitted structure is in the expanded state (FIG. 2). As discussed above, the hollow yarns14may be tubular to facilitate manufacturing. The breathability through the knitted structure12is greater when the knitted structure12is in the unexpanded state (FIG. 1) than when the knitted structure12is in the expanded state (FIG. 2). Accordingly, the breathability of the knitted structure12can be controlled to enhance comfort. The hollow yarns14may be partly or wholly made of an elastomer to facilitate expanding and contracting the hollow yarns14.

With continuing reference toFIGS. 1 and 2, the knitted structure12defines a plurality of pores20between the hollow yarns14. When the knitted structure is in the unexpanded state, pores20have a first average pore size PS1, and when the knitted structure is in the expanded state, the pores20have a second average pore size PS2. The second average pore size PS2is less than the first average pore size PS1. As such, the thermal conductivity of the knitted structure12is less when the knitted structure12is in the expanded state than when the knitted structure12is in the unexpanded state. Specifically, because the pores20contract in when the hollow yarns14are in the expanded state, the breathability and therefore thermal insulation capabilities of the knitted structure12decrease relative to the when the hollow yarns14are in the unexpanded state. As a result, the thermal conductivity of the knitted structure12is less when the knitted structure12is in the expanded state than when the knitted structure12is in the unexpanded state.

With reference toFIGS. 3 and 4, each of the hollow yarns14includes dopant particles22. In the depicted embodiment, the dopant particles22are entirely disposed inside the yarn body16for protection. Each of the dopant particles is a thermally conductive particle configured to conduct heat. As a non-limiting example, the dopant particles22may be wholly or partly made of a metallic material. When the hollow yarns14(and the knitted structure12shown inFIG. 1) are in the unexpanded (e.g., deflated) state, the dopant particles22are closer to each other than when the hollow yarns14(and the knitted structure12shown inFIG. 2) are in the expanded (e.g., inflated) state. Thus, the thermal conductivity of the hollow yarns14(and the knitted structure12shown inFIG. 1) is greater when the hollow yarns14(and the knitted structure12shown inFIG. 1) are in the unexpanded (e.g., deflated or when a vacuum is drawn inside the hollow yarns14) state than when the knitted structure12is in the expanded (e.g., inflated) state as the distance between the thermally conductive particles is increased. In addition, in the expanded state, the air pockets trapped in the hollow yarns14enhance the thermal insulation capabilities of the knitted structure12.

With reference toFIGS. 5 and 6, in some embodiments, the knitted structure12can be configured for fluid transport, delivery and removal in order to control temperature along the knitted structure12. Specifically, the hollow yarns14of the knitted structure12are configured to transport fluid through the yarn hole18. As discussed above, the yarn body16defines the yarn hole18. The yarn hole18extends through the yarn body16to fluid flow through the yarn body16in order to control the temperature of the knitted structure12. As discussed above, the hollow yarns14may be tubular to facilitate manufacturing. The hollow yarns14may be knitted and/or inlayed in a predetermined pattern for targeted temperature control. The knitted textile10includes a plurality of fluid lines24configured to transport a fluid (e.g., gas) into and out of the hollow yarns14. Accordingly, the fluid lines24are in fluid communication with the hollow yarns14.

Each of the hollow yarns14includes a circumferential wall32that defines an inner yarn surface26and an outer yarn surface28. The outer yarn surface28is opposite the inner yarn surface26. The inner yarn surface26defines the yarn hole18. Each of the hollow yarns14includes thermally-conductive particles30embedded in each of the hollow yarns14between the inner yarn surface26and the outer yarn surface28in order to maximize the thermal conductivity of each of the hollow yarns14. In this embodiment, the thermal conductivity of the thermally conductive particles30is greater than the thermal conductivity of the matrix of the hollow yarns14. As non-limiting examples, the thermally-conductive particles30may be wholly or partly made of silica aerogel and/or epoxy composite. Each thermally-insulating particle30is entirely disposed inside the yarn body16to enhance thermal insulation. Thus, each thermally-insulating particle30is entirely disposed between the inner yarn surface26and the outer yarn surface28for enhancing thermal transport. In the embodiment depicted inFIG. 6, except for the yarn hole18, the yarn body16is entirely solid such that no fluid can exit through the circumferential wall32of the yarn body16. Therefore, fluid can solely flow through the yarn hole18of the yarn body16. Alternatively, negative pressure can be applied to the porous tubular yarn14; this would draw air from the occupant, aiding in maintaining a comfortable thermal condition.

In the embodiment depicted inFIG. 7, the yarn hole18is a longitudinal hole extending along the length of the hollow yarn14, and each of the hollow yarns14is a porous tubular yarn that defines thru-holes34extending from the inner yarn surface26to the outer yarn surface28to allow a fluid flowing through the yarn hole18(i.e., the longitudinal hole) to exit the yarn body16through the thru-holes34. As a consequence, the fluid flowing through the yarn hole18can exit the yarn body16through the circumferential wall32, thereby allowing cooling (e.g., air cooling) of the knitted structure12.

With reference toFIGS. 8 and 9, the knitted textile10may include transparent, translucent and/or optically-active yarns36to control observable angles through the knitted structure12. The transparent yarns36may be wholly or partly made of polyester. Translucent yarns36may be wholly or partly made of fiber glass. The optically-active yarns36may be wholly or partly made of photonic crystal materials, photoluminescent materials, luminescent materials, light transmitting materials, and reflective material. As shown inFIG. 8, the large gaps between the transparent, translucent and/or optically-active yarns36allow light to pass through the knitted structure12relatively unimpeded. However, as shown inFIG. 9, the visibility through the knitted structure12is reduced (relative toFIG. 8) when the knitted structure12is viewed at an off-angle. Accordingly, the knitted structure12could serve as a privacy screen, allowing visibility solely at certain angles.

With reference toFIGS. 10 and 11, the knitted textile10includes a first knitted fabric layer38, a second knitted fabric layer40, and a knitted spacer fabric42directly interconnecting the first knitted fabric layer38and the second knitted fabric layer40. The knitted spacer fabric42includes a plurality of moisture-wicking yarns44that directly interconnect the first knitted fabric layer38and the second knitted fabric layer40to transport moisture from the first knitted fabric layer38toward the second knitted fabric layer40. Accordingly, the term “moisture-wicking yarn” means yarns that are specifically configured to move moisture by capillary action from the inside to the surface. As a non-limiting example, the moisture-wicking yarn44is wholly or partly made of a polyester blend. The second knitted fabric layer40includes a plurality of absorbent yarns46to collect the moisture transported from the first knitted fabric layer38to the second knitted fabric layer40through the plurality of moisture-wicking yarns44. For this reason, the first knitted fabric layer38is configured to face the occupant O, whereas the second knitted fabric layer40is configured to face away from the occupant O. The second knitted fabric layer40may include anti-microbial yarns48to kill bacteria. The second knitted fabric layer40includes yarn loops50(or other knitted feature) capable of maximizing the speed of moisture evaporation. Each of the absorbent yarns46includes a yarn body16and a yarn hole18extending through the yarn body16to allow air (or other suitable gas) to flow through the yarn body16. Each of the absorbent yarns46is wholly or partly made of a hygroscopic material to absorb moisture in response to the air A flowing through the yarn hole18of each of the absorbent yarns46.

In the embodiment depicted inFIG. 12, the yarn body16is wholly or partly made of a hygroscopic material configured to absorb moisture. Further, each of the absorbent yarns46includes a core52extending through the yarn hole18. The core52is wholly or partly made of a hydrophilic material to aid in a capillary action of moisture. Instead of the core52, a hydrophilic coating is applied on the interior of the yarn body16.

While the best modes for carrying out the teachings have been described in detail, those familiar with the art to which this disclosure relates will recognize various alternative designs and embodiments for practicing the teachings within the scope of the appended claims. The knitted textiles10illustratively disclosed herein may be suitably practiced in the absence of any element which is not specifically disclosed herein. Furthermore, the embodiments shown in the drawings or the characteristics of various embodiments mentioned in the present description are not necessarily to be understood as embodiments independent of each other. Rather, it is possible that each of the characteristics described in one of the examples of an embodiment can be combined with one or a plurality of other desired characteristics from other embodiments, resulting in other embodiments not described in words or by reference to the drawings. Alternatively, the interior hollow of the hygroscopic yarn can be coated with a hydrophilic coating to help pull moisture from the tube body and pass it down the tube length.