Patent Description:
Traditional spacer textiles comprise two layers of textiles joined together by tie yarns that are interlooped with yarns in the textile layers.

<CIT> relates to a three-dimensionally structured warp knitted fabric for use in the clothing and non-clothing fields as cushioning and filling materials.

<CIT> discloses a method for producing pillows and cushions with knit spacer fabrics of varying thickness.

<CIT> describes knit fabrics in which the technical face and technical back are both raised, and the technical face has an appearance different from the appearance of the technical back.

<CIT> discloses thermal blankets that comprise loop yarns of different pile heights and that include a unitary engineered thermal fabric.

<CIT> relates to a stretchable fabric having at least two different types of stretch elastic regions on the same fabric, and optionally having a coloured pattern applied thereto.

The subject matter of the present invention is defined by the appended independent claims. Preferred embodiments are the subject of the dependent claims.

Although the terms "step" and/or "block" might be used herein to connote different elements of methods employed, the terms should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly stated.

At a high level, aspects herein relate to a textile and garments formed from the textile. In one aspect, the textile comprises a three-dimensional (<NUM>-D) spacer textile with a first area having a first layer comprising, for instance, a mesh construction with integrally formed holes, a second layer comprising, for instance, a continuous knit construction, and a third layer that interconnects the first layer and the second layer. In aspects, the third layer comprises one or more multifilament tie yarns (also known as spacer yarns) that interconnect the first layer and the second layer. The textile further comprises at least a second area in which the first layer is absent or removed along with differing length portions of the tie yarns. The result is a textile that has the aesthetic and function of a plush or velour type textile having different length piles at the second area while the remaining areas of the textile have the aesthetic and function of a spacer textile.

In another aspect, the textile comprises a <NUM>-D spacer textile with a first area having a first layer comprising, for instance, a continuous knit construction knit using a fine denier (from about <NUM> dtex (<NUM> denier) to about <NUM> dtex (<NUM> denier)) yarn type, a second layer comprising, for instance, a continuous knit construction, and a third layer that interconnects the first layer and the second layer. In aspects, the third layer comprises one or more monofilament tie yarns that interconnect the first layer and the second layer. The textile further comprises at least a second area in which the first layer is absent or removed along with the monofilament tie yarns located in the second area. The result is a textile that comprises just the second layer at the second area while the remaining areas of the textile have the aesthetic and the function of a spacer textile.

In yet another aspect, the textile comprises a <NUM>-D spacer textile with a first area having a first layer comprising, for instance, a continuous knit construction knit using a fine denier (from about <NUM> dtex (<NUM> denier) to about <NUM> dtex (<NUM> denier)) yarn type, a second layer comprising, for instance, a continuous knit construction, and a third layer that interconnects the first layer and the second layer. In aspects, the third layer comprises one or more multifilament tie yarns that interconnect the first layer and the second layer. The textile further comprises at least a second area in which the first layer is absent or removed along with the "loop" portion of the tie yarns located in the second area. The result is a textile that has the aesthetic and function of a plush or velour type textile having a generally uniform pile length at the second area while the remaining areas of the textile have the aesthetic and function of a spacer textile.

Continuing, from a functional perspective, areas of the textile comprising the first layer, the second layer, and the third layer exhibit properties generally associated with spacer textiles such as cushioning properties, insulation (e.g., heated air is trapped or stored in the space between the first layer and the second layer), thermoregulation, and a level of air permeability that is generally greater than typical knit constructions such as single jersey or double jersey knits. The second areas described herein (e.g., areas at which the first layer and the tie yarns, or a portion of the length of the tie yarns, are absent or removed) generally exhibit a higher degree of air permeability as compared to areas of the textile comprising the first layer, the second layer, and the third layer. When the textile is incorporated into a garment, the second areas described herein may be positioned on the garment to correspond to high heat or sweat producing areas of the human body when the garment is in an as-worn configuration. Because these areas exhibit a higher degree of air permeability as compared to remaining portions of the textile, air from the external environment may more easily enter the garment at these areas thereby helping to cool the wearer, and heat and/or moisture vapor produced by the wearer may more easily escape the garment in these areas.

Aspects herein are further directed to a method of forming a textile having the properties described above. In aspects, the method may comprise applying an alkaline fiber-decomposing agent to a textile comprising a first layer formed from one or more cationic dyeable polyethylene terephthalate (CD PET) yarns, a second layer formed from non-CD PET yarns, and a third layer comprising one or more multifilament or monofilament CD PET yarns that interconnect the first layer and the second layer. More particularly, the alkaline fiber-decomposing agent is applied to the first layer of the textile in one or more predetermined areas. Application, in aspects, may occur via a digital printing process, an ink-jet printing process, a screen printing process, a roller printing process, and the like. The alkaline fiber-decomposing agent is configured to degrade the CD PET yarns in the first layer as well as at least a portion of the length of the CD PET multifilament or monofilament tie yarns in the third layer upon application of heat.

Continuing, parameters associated with the textile such as type of knit construction and/or the use of multifilament or monofilament tie yarns may be selected to achieve a particular aesthetic and functional effect. For instance, the selection of a continuous knit construction using fine dtex (denier) CD PET yarns for the first layer may facilitate the penetration of the alkaline fiber-decomposing agent through the first layer to the CD PET monofilament or multifilament tie yarns in the third layer. When CD PET monofilament yarns are selected for the third layer, the result is removal of the continuous knit first layer and removal of the monofilament tie yarns leaving just the second layer in areas of the textile to which the alkaline fiber-decomposing agent is applied. When CD PET multifilament yarns are selected for the third layer, the result is removal of the continuous knit first layer and the "loop" portion of the multifilament tie yarns producing a plush or pile effect in areas of the textile to which the alkaline fiber-decomposing agent is applied.

In another example, a mesh construction may be selected for the first layer along with CD PET multifilament tie yarns in the third layer. This selection allows for greater penetration of the alkaline fiber-decomposing agent through the holes in the mesh construction and less penetration of the alkaline fiber-decomposing agent through the remaining portions (i.e., non-hole portions) of the mesh construction. The result is removal of the first layer along with a portion of the length of the CD PET multifilament tie yarns in areas adjacent to the holes in the first layer and removal of the loop portion of the CD PET multifilament tie yarns in areas corresponding to the non-hole portions of the mesh construction. This produces variable length tie yarns in areas where the alkaline fiber-decomposing agent is applied.

Parameters associated with the alkaline fiber-decomposing agent may also be adjusted to facilitate the removal of the CD PET yarns in the first layer and some or all of the CD PET monofilament or multifilament yarns in the third layer. For instance, the type of alkaline fiber-decomposing agent, the amount of the alkaline fiber-decomposing agent applied to the textile, the concentration of the alkaline fiber-decomposing agent, and the like, may be controlled during the application step to remove varying lengths of the CD PET multifilament or monofilament tie yarns. As well, parameters associated with the heat application step such as time and temperature may be controlled to remove varying lengths of the CD PET multifilament or monofilament tie yarns. The non-CD PET yarns in the third layer are unaffected by the alkaline fiber-decomposing agent and, thus, the integrity or continuity of the third layer is maintained after the application and subsequent removal of the alkaline fiber-decomposing agent.

Accordingly, aspects herein are directed to an integral, three-dimensional spacer textile comprising a first area comprising a first layer having a mesh construction with a plurality of integrally formed holes, the first layer having at least a first outer surface defining a first outer surface plane, a second layer having at least a second inner surface, and a third layer, the third layer comprising a first multifilament tie yarn of a first plurality of multifilament tie yarns that interconnect the first layer and the second layer, the first multifilament tie yarn having a first length in the first area as measured between the second inner surface and the first outer surface plane. The spacer textile additionally comprises a second area comprising the second layer and a second multifilament tie yarn of a second plurality of multifilament tie yarns in the third layer, wherein the second multifilament tie yarn comprises a second length as measured between the second inner surface and a distal end of the second multifilament tie yarn in a direction extending toward the first outer surface plane, the second length less than the first length.

Aspects herein are further directed to a garment comprising an integral, three-dimensional spacer textile, the spacer textile comprising a first area having a first layer having a mesh construction, the first layer having at least a first outer surface defining a first outer surface plane, a second layer having at least a second inner surface, and a third layer, the third layer comprising a first multifilament tie yarn of a plurality of multifilament tie yarns that interconnect the first layer and the second layer, the first multifilament tie yarn having a first length in the first area as measured between the second inner surface and the first outer surface plane. The spacer textile further comprises a second area comprising the second layer and a second multifilament tie yarn of a second plurality of multifilament tie yarns in the third layer, wherein the second multifilament tie yarn comprises a second length as measured between the second inner surface and a distal end of the second multifilament tie yarn in a direction extending toward the first outer surface plane, the second length less than the first length.

Aspects herein are additionally directed to an integral three-dimensional spacer textile comprising a first area comprising a first layer having a continuous knit construction, the first layer having at least a first outer surface defining a first outer surface plane, a second layer having at least a second inner surface, and a third layer, the third layer comprising a first multifilament tie yarn of a first plurality of multifilament tie yarns that interconnect the first layer and the second layer, the first multifilament tie yarn having a first length in the first area as measured between the second inner surface and the first outer surface plane. The three-dimensional space textile further comprises a second area comprising the second layer and a second multifilament tie yarn of a second plurality of multifilament tie yarns in the third layer, wherein the second multifilament tie yarn comprises a second length as measured between the second inner surface and a distal end of the second multifilament tie yarn in a direction extending toward the first outer surface plane, the second length less than the first length.

Aspects herein are also directed to an integral three-dimensional spacer textile comprising a first area comprising a first layer having a continuous knit construction, the first layer having at least a first inner surface defining a first inner surface plane, a second layer having at least a second inner surface, and a third layer, the third layer comprising a first monofilament tie yarn of a first plurality of monofilament tie yarns that interconnect the first layer and the second layer, the first monofilament tie yarn having a first length in the first area as measured between the second inner surface and the first inner surface plane. The three-dimensional spacer textile also comprises a second area comprising the second layer and a second monofilament tie yarn of a second plurality of monofilament tie yarns in the third layer, wherein the second monofilament tie yarn comprises a second length as measured between the second inner surface and a distal end of the second monofilament tie yarn in a direction extending toward the first inner surface plane, the second length less than the first length.

Positional terms as used herein to describe a garment such as "anterior," "posterior," "front," "back," "upper," "lower," "inner-facing surface," "outer-facing surface," and the like are with respect to the garment being worn as intended and as shown and described herein by a wearer standing in an upright position. The term "spacer textile," as used herein is meant to encompass both warp knit and weft knit spacer textiles as is known in the art of textiles. Spacer textiles are generally formed by utilizing at least one tie yarn to interknit first and second layers of the textile. More specifically, each of the first layer and the second layer may be knit separately, and the tie yarn(s) is used to connect the first layer and the second layer. For instance, the tie yarns may have "loop" portions that extend into each of the first layer and the second layer where the loop portions are interlooped with yarns in the first layer and the second layer to connect the two layers. The distance between the first layer and the second layer may be varied by, for instance, varying the length of the tie yarn that extends between the first layer and the second layer. For example, the distance between the first layer and the second layer may be from about <NUM> to about <NUM> depending on the length of the tie yarn extending between the first layer and the second layer.

Because each of the first layer and the second layer are knit separately, each of the first layer, the second layer, and the third layer may be knit with different yarns and/or different yarn types. However, within a given layer (e.g., the first layer, the second layer, or the third layer), a particular yarn may extend throughout at least a portion of that layer. Because the first layer and the second layer may be knit independently of each other using different yarn types, the two layers may have different knit structures (e.g., mesh versus continuous) and exhibit different properties.

The term "terephthalate polymer-based" when describing, for example, a yarn means a yarn having filaments and/or fibers formed from terephthalate polymers and includes, for example, polyethylene terephthalate (PET), poly <NUM>,<NUM> cyclohexylene-dimethylene terephthalate (PCDT), polybutylene terephthalate (PCT) and polytrimethylene terephthalate (PTT). Aspects herein also contemplate using cationic-dyeable (CD) PET yarns. As used herein, CD PET yarns may comprise PET yarns which have been modified during polymerization to generate anionic sites (e.g., sulfonic acid groups). The term "non-CD PET yarns" as used herein refers to PET yarns that have not been modified as described herein. The term "non-CD PET yarns" may also refer to other non-PET yarn types such as polyamide yarns, cotton yarns, elastomeric yarns, and the like. The term "polyamide-based" when describing yarns means a yarn having filaments and/or fibers formed from any long-chain synthetic polyamide. The term "elastomeric" as used herein when describing yarns generally means a yarn type that may provide a maximum stretch greater than about <NUM>% under load prior to returning to its non-stretched state when the load is removed, and some elastomeric yarns provide a maximum stretch of about <NUM>%. Examples of elastomeric yarn types include Spandex®, lycra, rubber, and the like.

The term "mesh" as used herein means a textile having a knit construction where openings are created by modifying the knitting process used to form the textile (e.g., by dropping or transferring stiches). The term "continuous knit construction" as used herein means a textile having a continuous knit face without integrally formed or engineered openings (e.g., without intentionally dropped or transferred stitches). Examples would include a single jersey knit construction, a half tricot knit construction, a double jersey knit construction, and the like. The term "multifilament yarn" as used herein means a yarn having two or more filaments within a single yarn strand while the term "monofilament" as used herein means a yarn formed from a single filament.

As well, the term "integral" as used herein means a textile having at least one textile element (e.g., yarn, thread, filament, or fiber) that extends between different areas of a textile. For instance, with respect to the spacer textile described herein, the term "integral spacer textile" may mean a spacer textile having a continuous yarn that extends through different areas of the first layer and/or the second layer of the spacer textile, or a tie yarn that extends through different areas of at least the third layer of the spacer textile as well as portions of the first layer and the second layer. To describe this with respect to a knit construction, the term "integral spacer textile" may mean a spacer textile having a yarn from one area being interlooped with one or more knit courses of another area in the first layer and/or second layer and/or the third layer of the spacer textile. This may be opposed to a panel type construction where two or more separate materials are joined by affixing edges or surfaces by, for example, stitching, bonding, adhesives, and the like, such that there is not continuity of a yarn or textile element between the two materials.

Turning now to <FIG>, a spacer textile <NUM> is illustrated in accordance with aspects herein. The spacer textile <NUM> is provided to illustrate features associated with the tie yarns that interknit the different layers of the spacer textile <NUM> and to illustrate various reference planes that may be described with respect to aspects herein. The spacer textile <NUM> comprises a first layer <NUM> having a first inner surface <NUM> defining a first inner surface plane <NUM> that extends in an x-direction and a y-direction and a first outer surface <NUM> defining a first outer surface plane <NUM> extending in the x-direction and the y-direction. As described further below, the first layer <NUM> may comprise a continuous knit construction or a mesh knit construction in accordance with aspects herein, where the continuous knit construction or the mesh construction is formed using CD PET yarns.

Continuing, the spacer textile <NUM> further comprises a second layer <NUM> having a second inner surface <NUM> defining a second inner surface plane <NUM> extending in the x-direction and the y-direction and a second outer surface <NUM> defining a second outer surface plane <NUM> extending in the x-direction and the y-direction. In accordance with aspects herein, the second layer <NUM> may comprise a continuous knit construction formed using non-CD PET yarns. In aspects, non-CD PET yarns may comprise PET yarns, polyamide yarns, cotton yarns, elastomeric yarns, and the like.

The spacer textile <NUM> further comprises a third layer <NUM> comprising one or more tie yarns <NUM> that are interknitted with the first layer <NUM> and the second layer <NUM>. Although only one tie yarn <NUM> is shown for the third layer <NUM>, it is contemplated herein that the third layer <NUM> may be formed using more than one tie yarn. The portions of the tie yarn <NUM> indicated by the reference numerals <NUM> and <NUM> and shown in dashed lines to indicate they are generally hidden from view represent those areas of the tie yarn <NUM> that are interlooped with the yarns forming the first layer <NUM> and the second layer <NUM> respectively. As used throughout this disclosure, the term "loop" or "loop portion" when referring to tie yarns refers to the portion of the tie yarn that extends into the first layer <NUM> and the second layer <NUM> and is interlooped with yarns in the first layer <NUM> and the second layer <NUM>. To describe it a different way, the loop portion of the tie yarn is that portion of the tie yarn that does not extend between the first inner surface plane <NUM> and the second inner surface plane <NUM> of the spacer textile <NUM>. Aspects herein contemplate that the third layer <NUM> is formed using CD PET monofilament or multifilament yarns.

With this as reference and turning now to <FIG>, perspective views of a first spacer textile <NUM> are illustrated in accordance with aspects herein, where the space textile <NUM> is illustrated from two opposite surfaces. The spacer textile <NUM> comprises a first layer <NUM> (best shown in <FIG>), a second layer <NUM> opposite the first layer <NUM> (best shown in <FIG>), and a third layer <NUM> positioned primarily between the first layer <NUM> and the second layer <NUM>. With respect to <FIG>, the first layer <NUM> may be thought of as extending in a first x, y plane as shown by the arrows. Similarly, and with respect to <FIG>, the second layer <NUM> may also be thought of as extending in a second x, y plane, where the second x, y plane is offset from but generally parallel to the first x, y plane.

In one aspect, the first layer <NUM> comprises a mesh knit construction with a plurality of integrally formed holes <NUM>. The holes <NUM> may be knit to have one or more sizes and the hole size may be variable or uniform over the surface of the first layer <NUM>. As better depicted in <FIG>, the holes <NUM> extend through the thickness of the first layer <NUM> such that they are in fluid communication with the third layer <NUM> and with the space formed between the first layer <NUM> and the second layer <NUM>.

In aspects, the first layer <NUM> may be formed using a first yarn type comprising CD PET. The yarns forming the first layer may have a denier from about <NUM> D to about <NUM> D, from about <NUM> D to about <NUM> D, from about <NUM> D to about <NUM> D, or about <NUM> D (with <NUM> D = <NUM> dtex). As used herein, the term "about" means within ± <NUM>% of a designated value.

With respect to <FIG>, in aspects, the second layer <NUM> comprises a continuous knit construction without integrally formed holes. In aspects, the second layer <NUM> may be formed using at least a second yarn type comprising, for instance, polyamide. More specifically, the polyamide includes caprolactam (also known as nylon <NUM>). However, as noted above, the second layer <NUM> may also be formed using other non-CD PET yarns such as regular PET, cotton, and the like. The second layer <NUM> may be further formed using an elastomeric yarn type to provide stretch properties to the spacer textile <NUM>. More specifically, the second layer <NUM> may be formed using a caprolactam yarn that covers or is wrapped around an elastomeric core; the elastomeric core may comprise elastane. The covered yarn may have a denier from about <NUM> D to about <NUM> D, from about <NUM> D to about <NUM> D, from about <NUM> D to about <NUM> D, or about <NUM> D.

In aspects, the third layer <NUM> comprises one or more multifilament tie yarns <NUM> that are interknitted with the first layer <NUM> and the second layer <NUM> so as to interconnect these layers. As explained further below with respect to <FIG>, the non-loop portions of the tie yarns <NUM> may have a predetermined length as measured between the inner-facing surface of the first layer <NUM> and the inner-facing surface of the second layer <NUM> so as to space apart the first layer <NUM> and the second layer <NUM> by a predetermined amount such as, for example, about <NUM>.

Continuing, the distance between adjacent tie yarns <NUM> (as measured in for example, the x-direction and the y-direction) may be adjusted to provide varying degrees of compressibility of the spacer textile <NUM>. For instance, the spacing may be decreased (e.g., more tie yarns per given area) to decrease the compressibility of the spacer textile <NUM>, and the spacing may be increased (e.g., less tie yarns per given area) to increase the compressibility of the spacer textile <NUM>. Thus, although the tie yarns <NUM> are shown in <FIG> as being spaced apart a certain distance, it is contemplated herein that other spacing configurations may be used. Further, although the tie yarns <NUM> are shown as extending in a vertical orientation between the first layer <NUM> and the second layer <NUM> such that they are generally perpendicular to the first layer <NUM> and the second layer <NUM>, it is contemplated herein that the tie yarns <NUM> may comprise other orientations instead of vertical. For instance, when the spacer textile <NUM> is in an uncompressed state (i.e., a resting state) the tie yarns <NUM> may be positioned generally perpendicular to the first layer <NUM> and the second layer <NUM> or may be skewed from a vertical orientation by up to, for example, ± <NUM> degrees.

Continuing, in aspects, the tie yarns <NUM> may be formed of a third yarn type where the third yarn type comprises CD PET. The yarns forming the third layer may have a denier from about <NUM> D to about <NUM> D, from about <NUM> D to about <NUM> D, from about <NUM> D to about <NUM> D, or about <NUM> D. Each of the tie yarns <NUM> may comprise from about <NUM> to about <NUM> filaments per tie yarn, from about <NUM> to about <NUM> filaments per tie yarn, from about <NUM> to about <NUM> filaments per tie yarn, or about <NUM> filaments per tie yarn.

<FIG> illustrates a cross-section view or side view of the spacer textile <NUM> in accordance with aspects herein. As shown, the first layer <NUM> of the spacer textile <NUM> may comprise a first inner surface <NUM> and a first outer surface <NUM> opposite the first inner surface <NUM>. The holes <NUM> extending through the first layer <NUM> are shown in <FIG>. As described above, the first layer <NUM> may be thought of as extending along an x, y plane. More specifically, the first inner surface <NUM> may extend along or define a first inner surface plane as represented by arrows <NUM>, where the first inner surface plane <NUM> extends in an x-direction and a y-direction. And the first outer surface <NUM> may extend along or define a first outer surface plane as represented by arrows <NUM>, where the first outer surface plane <NUM> extends in an x-direction and a y-direction. As well, the second layer <NUM> of the spacer textile <NUM> may comprise a second inner surface <NUM> and a second outer surface <NUM> opposite the second inner surface <NUM>. Similar to the first inner surface <NUM>, the second inner surface <NUM> may also extend along or define a second inner surface plane as represented by arrows <NUM>, where the second inner surface plane <NUM> extends in an x-direction and a y-direction and where the second inner surface plane <NUM> is parallel to but offset from the first inner surface plane <NUM>. As well, the second outer surface <NUM> may extend along or define a second outer surface plane as represented by arrows <NUM>, where the second outer surface plane <NUM> extends in an x-direction and a y-direction.

Continuing with respect to <FIG>, the tie yarns <NUM> are shown extending between at least the first inner surface <NUM> of the first layer <NUM> and the second inner surface <NUM> of the second layer <NUM> with loop portions <NUM> of the tie yarns <NUM> extending into the first layer <NUM> and loop portions <NUM> of the tie yarns <NUM> extending into the second layer <NUM> to interconnect the layers <NUM> and <NUM>. To describe this a different way, for the spacer textile <NUM> shown in <FIG>, the non-loop portions of the tie yarns <NUM> extend between at least the second inner surface plane <NUM> and the first inner surface plane <NUM>.

As described above, it is contemplated herein that the loop portions <NUM> and <NUM> of the tie yarns <NUM> may extend into the first layer <NUM> and the second layer <NUM> respectively. As such, a particular tie yarn, such as tie yarn <NUM> may comprise a first length <NUM> as measured between the second inner surface <NUM> (or the second inner surface plane <NUM>) and the loop portion <NUM> of the tie yarn <NUM> in the direction of the first outer surface plane <NUM>. Because of variabilities in the knitting process used to create the spacer textile <NUM>, it is contemplated that the tie yarns <NUM> may not comprise all the same length (e.g., first length <NUM>), but instead, the tie yarns <NUM> may comprise a first average length.

Turning now to <FIG>, a perspective view of the spacer textile <NUM> is shown after a portion of the first layer <NUM> has been removed at a second area <NUM> of the spacer textile <NUM> and after variable length portions of the multifilament tie yarns <NUM> have been removed in the second area <NUM> (now labelled as tie yarns <NUM> and <NUM>). Remaining areas of the spacer textile <NUM> excluding the second area <NUM> may be known herein as a first area(s) <NUM>. To describe this differently, <FIG> depicts the spacer textile <NUM> as comprising at least a first area <NUM> having the first layer <NUM>, the second layer <NUM>, and the third layer <NUM>, and at least a second area <NUM> having the second layer <NUM>, a portion of the third layer <NUM>, and no first layer <NUM>. As will be explained in greater depth below, an alkaline fiber-decomposing agent may be applied to the first layer <NUM> at the second area <NUM> using example application processes. The alkaline fiber-decomposing agent is configured to remove/degrade the CD PET yarns in the first layer <NUM> at the second area <NUM>. As well, the alkaline fiber-decomposing agent is configured to remove at least a portion of the length of the CD PET multifilament tie yarns <NUM> in the second area <NUM>. The second layer <NUM>, formed from non-CD PET yarns, and/or polyamide-based yarn types and elastomeric yarn types is unaffected by the alkaline fiber-decomposing agent.

With this as background and with respect to <FIG>, the second area <NUM> is shown as having a generally rectangular shape but it is contemplated that the second area <NUM> may comprise any shape including shapes associated with branding such as logos, images, and the like, geometric shapes, organic shapes, letters, numbers, and the like. Moreover, although only one second area <NUM> is shown, it is contemplated herein that the spacer textile <NUM> may comprise multiple second areas <NUM> with each second area <NUM> having the same shape or a different shape. When the spacer textile <NUM> comprises multiple second areas <NUM>, it is contemplated herein that the first area <NUM> may extend around or circumscribe at least a portion of the second areas <NUM>. Any and all aspects, and any variation thereof, are contemplated as being within aspects herein.

As mentioned, in the second area <NUM>, the first layer <NUM> is removed or absent along with variable length portions of the tie yarns <NUM>. More particularly with respect to the tie yarns in the second area <NUM>, tie yarns located in areas adjacent to the holes <NUM> in the first layer <NUM> prior to application of the alkaline fiber-decomposing agent, such as tie yarns <NUM>, may have a greater portion of their length removed as compared to tie yarns located in areas positioned further away from the holes <NUM> in the first layer <NUM> prior to the application of the alkaline fiber-decomposing agent, such as tie yarns <NUM>. In aspects, this may be due to a greater penetration of the alkaline fiber-decomposing agent through the holes <NUM> as compared to the penetration of the alkaline fiber-decomposing agent in the non-hole areas of the first layer <NUM>. Because of the greater penetration of the alkaline fiber-decomposing agent through the holes <NUM>, tie yarns located adjacent to the holes <NUM> may be degraded to a greater extent than tie yarns located further away from the holes <NUM>. Further, with respect to the tie yarns located further away from the holes, it is contemplated herein that the loop portion <NUM> of these tie yarns may be removed or degraded upon application of the alkaline fiber-decomposing agent to the first layer <NUM>, but the remaining length of the tie yarns (e.g., the length between the first inner surface plane <NUM> and the second inner surface plane <NUM>) may still be present.

With respect to particular yarns located in the second area <NUM> (e.g., tie yarn <NUM> and tie yarn <NUM>), when a portion of the length of the tie yarn <NUM> is removed, or when the loop portion of the tie yarn <NUM> is removed, it is contemplated that the integrity of the multifilament yarn strand forming the tie yarns <NUM> and <NUM> is disrupted so that the filaments within the tie yarns <NUM> and <NUM> are no longer tightly packed at least at their distal ends (i.e., the end closest to the first inner surface plane <NUM>) such that the filaments spread out with respect to one another. The result is that areas surrounding the second area <NUM> (e.g., the first area <NUM>) have the look of a spacer textile, while the second area <NUM> has the look of a plush or pile-type textile with variable length yarns (e.g., tie yarns <NUM> and tie yarns <NUM>). Functionally, the spacer textile <NUM> shown in <FIG> would exhibit functional properties associated with spacer textiles in the first area <NUM> such as compressibility, insulation, thermoregulation, and increased air permeability as compared to non-spacer textile knit constructions. Because the second area <NUM> comprises a more open construction with the first layer <NUM> being absent along with variable length portions of the tie yarns, the second area <NUM> generally exhibits a higher level of air permeability as compared to the first area <NUM> of the spacer textile.

<FIG> depicts a cross-section view of the spacer textile <NUM> of <FIG> in accordance with aspects herein. As seen, in the second area <NUM>, the first layer <NUM> is absent and the tie yarns <NUM> and <NUM> in the second area <NUM> comprise at least two different lengths. To aid in the following disclosure, the area where the first layer <NUM> was present prior to removal is shown in dashed lines to provide an indication of the location of the holes <NUM> and the non-hole areas of the removed first layer <NUM>. The tie yarns <NUM> located adjacent to the holes <NUM> (i.e., the tie yarns <NUM> located along a reference line or reference plane extending through the holes <NUM> in a direction toward the second layer <NUM>) are shown as having a shorter length as compared to the tie yarns <NUM> located further away from the holes <NUM> (i.e., the tie yarns <NUM> that would not be intersected by a reference line or reference plane extending through the holes <NUM> in a direction toward the second layer <NUM>). For example, the tie yarns <NUM> may comprise a second length <NUM> as measured between the second inner surface <NUM> (or second inner surface plane <NUM>) and a distal end of the tie yarns <NUM> in a direction extending toward the first outer surface plane <NUM>. In aspects, the second length <NUM> of the tie yarns <NUM> is less than the first length <NUM> of the tie yarn <NUM> in the first area <NUM>. Moreover, it is contemplated herein that the second length <NUM> of the tie yarns <NUM> is greater than zero (i.e., not all of the length of the tie yarns <NUM> is removed).

Continuing, the tie yarns <NUM> located in the non-hole portions of the removed first layer <NUM> may comprise a third length <NUM> as measured between the second inner surface <NUM> (or second inner surface plane <NUM>) and a distal end of the tie yarns <NUM> in a direction extending toward the first outer surface plane <NUM>. In aspects, the third length <NUM> of the tie yarns <NUM> may be greater than the second length <NUM> of the tie yarns <NUM> but less than the first length <NUM> of the tie yarn <NUM> in the first area <NUM>. Because of variabilities in the process used to remove the first layer <NUM> and a portion of the length of the tie yarns <NUM> and <NUM> in the second area <NUM>, it is contemplated that the tie yarns <NUM> in the second area <NUM> may not comprise all the same length (e.g., second length <NUM>) and it is further contemplated herein that the tie yarns <NUM> in the second area <NUM> may not comprise all the same length (e.g., third length <NUM>).

Turning now to <FIG>, a second configuration for a spacer textile <NUM> is provided in accordance with aspects herein. With respect to <FIG>, which illustrates a cross-section view of the spacer textile <NUM>, the spacer textile <NUM> comprises a first layer <NUM>, a second layer <NUM>, and a third layer <NUM> that interconnects the first layer <NUM> and the second layer <NUM>. In aspects, the first layer <NUM> comprises a continuous knit construction formed using CD PET yarns having a denier from about <NUM> denier to about <NUM> denier, from about <NUM> denier to about <NUM> denier, or about <NUM> denier. The second layer <NUM> may also comprise a continuous knit construction formed using non-CD PET yarns. In aspects, the non-CD PET yarns may comprise polyamide yarns and elastomeric yarns, and, in aspects, the elastomeric yarns may be wrapped with the polyamide yarns such that the yarns have a denier from about <NUM> denier to about <NUM> denier, from about <NUM> denier to about <NUM> denier, or from about <NUM> denier to about <NUM> denier. In aspects, the third layer <NUM> may comprise one or more monofilament CD PET tie yarns <NUM> having a denier from about <NUM> denier to about <NUM> denier, from about <NUM> denier to about <NUM> denier, or about <NUM> denier.

Similar to the spacer textile <NUM>, the first layer <NUM> of the spacer textile <NUM> has a first inner surface <NUM> defining a first inner surface plane <NUM> and a first outer surface <NUM> defining a first outer surface plane <NUM>. The second layer <NUM> of the spacer textile <NUM> comprises a second inner surface <NUM> defining a second inner surface plane <NUM> and a second outer surface <NUM> defining a second outer surface plane <NUM>.

The monofilament tie yarns <NUM> that form the third layer <NUM> comprise loop portions <NUM> that are interlooped with yarns forming the first layer <NUM> and loop portions <NUM> that are interlooped with yarns forming the second layer <NUM> to interconnect the two layers <NUM> and <NUM>. The non-loop portions of the tie yarns <NUM> extend between the first inner surface <NUM> and the second inner surface <NUM>. In aspects, the tie yarns <NUM> may comprise at least a first length <NUM> as measured between the second inner surface <NUM> (or second inner surface plane <NUM>) to the loop portion <NUM> of the tie yarns <NUM> in a direction extending toward the first outer surface <NUM> (or first outer surface plane <NUM>).

<FIG> depicts a perspective view of the spacer textile <NUM> after an alkaline fiber-decomposing agent has been applied to a second area <NUM> of the spacer textile <NUM> to remove the first layer <NUM> in the second area <NUM> along with the monofilament tie yarns <NUM> that were located in the second area <NUM>. Remaining areas of the spacer textile <NUM> excluding the second area <NUM> may be known herein as a first area(s) <NUM>. To describe this differently, <FIG> depicts the spacer textile <NUM> as comprising at least a first area <NUM> having the first layer <NUM>, the second layer <NUM>, and the third layer <NUM>, and at least a second area <NUM> having only the second layer <NUM> (i.e., no first layer <NUM> and no third layer <NUM>). The use of fine denier yarns to knit the first layer <NUM> may allow for greater penetration of the alkaline fiber-decomposing agent into the third layer <NUM>. This coupled with the use of fine denier monofilament CD PET tie yarns as opposed to multifilament tie yarns facilitates the degradation and removal of the tie yarns <NUM> by the alkaline fiber-decomposing agent.

Although the second area <NUM> is shown as having a generally rectangular shape, it is contemplated that the second area <NUM> may comprise any shape including shapes associated with branding such as logos, images, and the like, geometric shapes, organic shapes, letters, numbers, and the like. Moreover, although only one second area <NUM> is shown, it is contemplated herein that the spacer textile <NUM> may comprise multiple second areas <NUM> with each second area <NUM> having the same shape or a different shape. When the spacer textile <NUM> comprises multiple second areas <NUM>, it is contemplated herein that the first area <NUM> may extend around or circumscribe at least a portion of the second areas <NUM>. Any and all aspects, and any variation thereof, are contemplated as being within aspects herein.

With continued respect to <FIG>, the areas surrounding the second area <NUM> (e.g., the first area <NUM>) have the look and function of a spacer textile, while the second area <NUM> comprises just the second layer <NUM>. Functionally, the spacer textile <NUM> would exhibit functional properties associated with spacer textiles in the first area <NUM> such as compressibility, insulation, thermoregulation, and increased air permeability as compared to non-spacer textile knit constructions. Because the second area <NUM> comprises a more open construction with the first layer <NUM> and the tie yarns <NUM> being removed, the second area <NUM> may exhibit a higher level of air permeability as compared to the first area <NUM> of the spacer textile <NUM>.

<FIG> depicts a cross-section view or side view of the spacer textile <NUM> of <FIG> in accordance with aspects herein. As seen, in the second area <NUM>, the first layer <NUM> is absent along with the tie yarns <NUM> such that the second area <NUM> comprises only the second layer <NUM> without the first layer <NUM> and without the tie yarns <NUM>. The first area <NUM> comprises the first layer <NUM>, the second layer <NUM>, and the third layer <NUM>, where the third layer comprises the tie yarns <NUM> having the first length <NUM>.

Turning now to <FIG>, a third configuration is provided in accordance with aspects herein. With respect to <FIG>, a cross-section of a spacer textile <NUM> is shown where the spacer textile comprises a first layer <NUM>, a second layer <NUM>, and a third layer <NUM> that interconnects the first layer <NUM> and the second layer <NUM>. In aspects, the first layer <NUM> comprises a continuous knit construction formed using CD PET yarns having a denier from about <NUM> denier to about <NUM> denier, from about <NUM> denier to about <NUM> denier, or about <NUM> denier. The second layer <NUM> may also comprise a continuous knit construction formed using non-CD PET yarns. In aspects, the non-CD PET yarns may comprise polyamide yarns and elastomeric yarns, and, in aspects, the elastomeric yarns may be wrapped with the polyamide yarns such that the yarns have a denier from about <NUM> denier to about <NUM> denier, from about <NUM> denier to about <NUM> denier, or from about <NUM> denier to about <NUM> denier. In aspects, the third layer <NUM> may comprise one or more multifilament CD PET tie yarns <NUM> having a denier from <NUM> D to about <NUM> D, from about <NUM> D to about <NUM> D, from about <NUM> D to about <NUM> D, or about <NUM> D. Each of the tie yarns <NUM> may comprise from about <NUM> to about <NUM> filaments per tie yarn, from about <NUM> to about <NUM> filaments per tie yarn, from about <NUM> to about <NUM> filaments per tie yarn, or about <NUM> filaments per tie yarn.

Similar to the spacer textile <NUM> and the spacer textile <NUM>, the first layer <NUM> of the spacer textile <NUM> has a first inner surface <NUM> defining a first inner surface plane <NUM> and a first outer surface <NUM> defining a first outer surface plane <NUM>. The second layer <NUM> of the spacer textile <NUM> comprises a second inner surface <NUM> defining a second inner surface plane <NUM> and a second outer surface <NUM> defining a second outer surface plane <NUM>.

The multifilament tie yarns <NUM> that form the third layer <NUM> comprise loop portions <NUM> that are interlooped with yarns forming the first layer <NUM> and loop portions <NUM> that are interlooped with yarns forming the second layer <NUM> to interconnect the two layers <NUM> and <NUM>. The non-loop portions of the tie yarns <NUM> extend between the first inner surface <NUM> and the second inner surface <NUM> such that the tie yarns <NUM> comprise at least a first length <NUM> as measured between the second inner surface <NUM> (or second inner surface plane <NUM>) and the loop portion <NUM> of the tie yarns <NUM> in a direction extending toward the first outer surface <NUM> (or the first outer surface plane <NUM>).

<FIG> depicts a perspective view of the spacer textile <NUM> after an alkaline fiber-decomposing agent has been applied to a second area <NUM> of the spacer textile <NUM> to remove the first layer <NUM> in the second area <NUM> along with the loop portions <NUM> of the multifilament tie yarns that were located in the second area <NUM> (now labelled as tie yarns <NUM>). Remaining areas of the spacer textile <NUM> excluding the second area <NUM> may be known herein as a first area(s) <NUM>. To describe this differently, <FIG> depicts the spacer textile <NUM> as comprising at least a first area <NUM> having the first layer <NUM>, the second layer <NUM>, and the third layer <NUM>, and at least a second area <NUM> having the second layer <NUM> and the tie yarns <NUM> without their loop portions <NUM>. The use of fine denier yarns to knit the first layer <NUM> may allow for greater penetration of the alkaline fiber-decomposing agent into the loop portions <NUM> of the tie yarns <NUM> thereby helping to remove or degrade the loop portions <NUM> of the tie yarns <NUM> in the second area <NUM>.

Similar to the spacer textile <NUM>, when the loop portion <NUM> of the tie yarns <NUM> are removed, the integrity of the multifilament yarn strand forming the ties yarns <NUM> is disrupted such that the filaments within the yarn strand are no longer tightly packed together at least at their distal ends (the end closest to the first inner surface plane <NUM>) such that the filaments spread out with respect to one another. Thus, the areas surrounding the second area <NUM> (e.g., the first area <NUM>) have the look of a spacer textile, while the second area <NUM> has a plush or pile-type look with generally uniform length tie yarns <NUM>. Functionally, the spacer textile <NUM> would exhibit functional properties associated with spacer textiles in the first area <NUM> such as compressibility, insulation, thermoregulation, and increased air permeability as compared to non-spacer textile knit constructions. Because the second area <NUM> comprises just the second layer <NUM> and the tie yarns <NUM>, the second area <NUM> may exhibit a higher level of air permeability as compared to the first area <NUM> of the spacer textile <NUM>.

<FIG> depicts a cross-section view of the spacer textile <NUM> of <FIG> in accordance with aspects herein. As seen, in the second area <NUM>, the first layer <NUM> is absent and the tie yarns <NUM> in the second area <NUM> lack their loop portions <NUM>. For example, the tie yarns <NUM> may comprise a second length <NUM> as measured between the second inner surface <NUM> (or second inner surface plane <NUM>) and a distal end of the tie yarns <NUM> in a direction extending toward the first outer surface plane <NUM>. In aspects, the second length <NUM> of the tie yarns <NUM> is less than the first length <NUM> of the tie yarns <NUM> in the first area <NUM>. Moreover, it is contemplated herein that the second length <NUM> of the tie yarns <NUM> is greater than zero (i.e., not all of the tie yarn <NUM> is removed). Because of variabilities in the process used remove the first layer <NUM> and a portion of the length of the tie yarns <NUM> in the second area <NUM>, it is contemplated that the tie yarns <NUM> in the second area <NUM> may not comprise all the same length (e.g., second length <NUM>) but, instead may have an average length that is less than the first length <NUM>.

Aspects herein contemplate incorporating the textiles described herein (e.g., spacer textiles <NUM>, <NUM>, and/or <NUM>) in a garment. When incorporated into a garment, it is contemplated that the first areas of the textile (i.e., the areas comprising the first layer, the second layer, and the third layer) may be positioned in areas of the garment needing, for instance, increased cushioning (e.g., pressure areas such as elbow regions, shoulder regions, knee regions, and the like) and/or areas needing increased insulation. The second areas of the textile (i.e., the areas where the first layer and a portion of the length of the tie yarns are absent or removed) would be positioned in areas of the garment corresponding to high heat and/or sweat producing areas of the human body when the garment is worn. Because these areas have a higher air permeability as compared to, for instance, areas of the textile comprising the first layer, the second layer, and the third layer, air from the external environment may more readily enter the garment to help cool the wearer, and heat produced by the wearer may more readily escape the garment further helping to keep the wearer cool.

A garment <NUM> is shown in <FIG> in accordance with aspects herein. The garment <NUM> is shown in the form of an upper-body garment (e.g., a vest), but it is contemplated herein that the garment <NUM> may be in the form of a lower-body garment, a whole body garment, and the like. Moreover, although shown in the form of a vest, it is contemplated herein that the garment <NUM> may take other forms such as a jacket, a pull-over, a hoodie, a shirt, and the like. Any and all aspects, and any variation thereof, are contemplated as being within aspects herein. In aspects, the garment <NUM> may be entirely formed from one of the spacer textiles described herein. Alternatively, one or more portions of the garment <NUM> may be formed from one or more of the spacer textiles described herein and other portions of the garment <NUM> may be formed from other textile types (e.g., woven, non-woven, different knit constructions, and the like). To simplify the discussion, the garment <NUM> will be described as being formed entirely from the spacer textile <NUM>. However, as previously discussed, it is contemplated herein that the garment <NUM> may also be formed from the spacer textile <NUM> or the spacer textile <NUM>.

With respect to the garment <NUM>, in aspects it is contemplated that the first layer <NUM> of the spacer textile <NUM> may comprise an outer-facing surface <NUM> of the garment <NUM>. The second layer <NUM> of the spacer textile <NUM> forms an inner-facing surface of the garment <NUM> (not shown in <FIG>). In an alternative aspect (not shown), the first layer <NUM> of the spacer textile <NUM> may comprise an inner-facing surface of the garment <NUM>. The second layer <NUM> in this aspect would form the outer-facing surface of the garment <NUM>. Any and all aspects, and any variation thereof, are contemplated as being within aspects herein.

As shown in <FIG>, the garment <NUM> comprises at least one area <NUM> from which the first layer <NUM> and the loop portion <NUM> of the tie yarns <NUM> are removed. Although the area <NUM> is shown as diamond shaped, it is contemplated herein that the shape of the area <NUM> may comprise other shapes such as shapes associated with branding (e.g., logos or images), other geometric shapes, organic shapes, and the like. The area <NUM> is positioned on the garment <NUM> at a front upper torso portion of the garment <NUM>. In aspects, this area may correspond to a high heat or sweat producing area of a wearer when the garment <NUM> is worn as based on, for example, heat or sweat maps of the human body. The location of the area <NUM> on the garment <NUM> is illustrative only and it is contemplated herein that the garment <NUM> may comprise other areas from which the first layer <NUM> and the loop portion <NUM> of the tie yarns <NUM> are removed (e.g., back torso portion).

Turning now to <FIG>, a flow diagram is depicted of a method <NUM> of forming a spacer textile such as the spacer textile <NUM>, the spacer textile <NUM> or the spacer textile <NUM> having one or more areas at which the first layer of the spacer textile is removed along with all of the tie yarns (such as spacer textile <NUM>) or a portion of the length of the tie yarns (such as spacer textile <NUM> or spacer textile <NUM>). At a step <NUM>, an alkaline fiber-decomposing agent is applied to a first layer of a spacer textile at one or more discrete areas where the spacer textile comprises the first layer, a second layer, and a third layer, and where the third layer is interknitted with the first layer and the second layer. In aspects the first layer is formed from CD PET yarns, the second layer is formed from non-CD PET yarns (e.g., regular PET yarns, polyamide yarns, elastomeric yarns, cotton yarns, and the like), and the third layer is formed from either monofilament CD PET yarns or multifilament CD PET yarns.

In aspects, the alkaline fiber-decomposing agent may comprise an alkali having a pH of at least <NUM>. Some examples of suitable alkaline fiber-decomposing agents include guanidine weak acid salts, phenols, alcohols, alkali metal hydroxides, and alkaline earth metal hydroxides. It is contemplated herein that the alkaline fiber-decomposing agent be dissolved in water to make it suitable for application. Suitable concentrations may comprise from about <NUM> wt% to about <NUM> wt%.

In aspects, the alkaline fiber-decomposing agent may be applied by a digital printing process, a screen printing process, an ink-jet printing process, a roller printing process, and the like. Moreover, parameters associated with the alkaline fiber-decomposing agent may be adjusted during the application process. For instance, the amount of alkaline fiber-decomposing agent applied may be adjusted by utilizing, for example, a two pass or multiple pass printing process as opposed to a single pass. In aspects, the amount of the alkaline fiber-decomposing agent applied may range from about <NUM>/m<NUM> to about <NUM>/m<NUM>.

Continuing, at a step <NUM>, a heat treatment is applied to the textile to facilitate the removal and/or degradation of the CD PET yarns. In aspects, the temperature may be from about <NUM> to about <NUM>, and the textile may be subjected to the increased temperature for about <NUM> minutes. At a step <NUM>, the textile is cleaned to remove any residual alkaline fiber-decomposing agent and to remove any decomposed/degraded yarns. One cleaning method is reduction cleaning using hydrosulfite, surfactant, and soda ash.

The method may further comprise incorporating the spacer textile into a garment. In this aspect, the spacer textile is incorporated into a garment such that the areas at which the first layer is removed along with a portion of the length of the tie yarns is positioned on the garment to correspond to high heat or sweat producing areas of the human body when the garment is worn.

Claim 1:
An integral spacer textile (<NUM>) comprising:
a first outer surface (<NUM>) oriented in a first direction and a second outer surface (<NUM>) oriented in a second direction, opposite to the first direction;
a first area (<NUM>) comprising a spacer textile that includes a first knit layer (<NUM>), a second knit layer (<NUM>), and a third layer (<NUM>), the third layer (<NUM>) comprising monofilament tie yarns (<NUM>) that interconnect the first knit layer (<NUM>) and the second knit layer (<NUM>);
in the first area (<NUM>), the first knit layer (<NUM>) comprises the first outer surface (<NUM>) of the integral spacer textile (<NUM>) oriented in the first direction, and the second knit layer (<NUM>) comprises the second outer surface (<NUM>) of the integral spacer textile (<NUM>) oriented in the second direction;
and characterized by further comprising
a second area (<NUM>) circumscribed by the first area (<NUM>), which forms a boundary around the second area (<NUM>), wherein within the boundary, the monofilament tie yarns (<NUM>) are absent from the integral spacer textile (<NUM>) and the second knit layer (<NUM>) comprises the first outer surface (<NUM>) of the integral spacer textile (<NUM>) and the second outer surface (<NUM>) of the integral spacer textile (<NUM>),
wherein the first layer (<NUM>) is formed from a first yarn type comprising a cationic dyeable polyethylene terephthalate (CD PET).