Inventors: Michelle Greenlee, Cara Campagnoli & Brigham Pierce BACKGROUND

The innovations disclosed herein relate generally to a three-dimensional knit or woven fabric which defines a matrix for holding and dispensing an aggregation of fine particulates, e.g., a powder. The fabric is particularly suited for holding a chalk powder that is loadable into and normally retained in the matrix but which can be dispensed to an exterior surface of the matrix by manual interaction with the surface. As example applications, the innovations provide effective ways to dispense chalk to the hands for rock climbers, gymnasts, weight lifters, baseball pitchers, construction workers, etc. The innovations include articles of manufacture that incorporate the fabric, including apparel, footwear, packs, bags, personal articles, and equipment at activity centers, such as gyms.

As used herein,“innovations” refers to any one or more items of subject matter or combinations of subject matter disclosed herein that are considered patentable.

Articles for dispensing chalk and other powders are known and disclosed in US Patent documents: US4448560, 5609419, US6349414, and US20140348567.

However, such prior approaches do not adequately hold powder and/or control the dispensation of the powder. They also may not provide other advantages, such as hand cleaning and moisture wicking. They may be difficult or expensive to manufacture. They may not offer material or physical properties or aesthetics that lend to integration in standard articles of manufacture, such as apparel or footwear. They may also be cumbersome to use or difficult to wash.

Accordingly, a need exists for improved fabrics for holding and dispensing aggregations of fine particles like chalks, and better forms of integrated products.

Summary

In certain embodiments, the innovations are directed to a construct comprising a 3D spacer fabric, the 3D fabric having a first fabric layer and a second fabric layer, the first layer being relatively pervious to chalk or other fine particles, and the second layer being relatively impervious to the particles; a plurality of pile yarns, the first and second layers being sufficiently spaced apart by at least some of the pile yams such that the layers define a reservoir for the particles and substantially retain the particles in the reservoir until a trigger event; and wherein the panel is configured so that particles are preferentially released through a pervious surface of the first layer on the trigger event. In the foregoing embodiment and others, the trigger event may be a sufficient compression of the first layer towards the second layer, and/or forced application of air or other fluid into reservoir, sufficient to displace the particles preferentially through the surface of the first layer.

In the foregoing embodiment and others, the first layer may be a mesh having a plurality of openings over its surface area through which the fine particles can pass.

In the foregoing embodiment and others, the pile yarns separating the layers may be structural pile yams that interconnect the first and second layers, maintain the separation of the layers, and resiliently return the separation of the layers after removal of a force that displaces the layers from a static condition.

In the foregoing embodiment and others, the pile yarns may include a plurality of particle retention yarns that extend at least partially from a surface of the first and/or second layers into the space of the reservoir, the particle retention yarns being configured to interact with the particles and retain the particles until a trigger event causes displacement of the particles away from the particle retention yarns.

Other embodiments are contemplated in the Detailed Description below and in the appended Figures, and in the claims, as originally written or amended, the claims as such being incorporated by reference into this Summary.

The following is a description of various lines of innovations under the inventive subject matter. The appended claims, as originally filed in this document, or as subsequently amended, are hereby incorporated into this Summary section as if written directly in.

Other embodiments are contemplated in the detailed description below and in the appended Figures, and in the claims, as originally written or amended, and the claims as such being incorporated by reference into this Summary. Persons skilled in the art can appreciate such other embodiments and features from the following detailed description in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The appended figures show embodiments according to the inventive subject matter, unless noted as showing prior art.

FIG. 1 shows a top view of a pair of panel, each with a reservoir for fine particles integrated into an article of manufacture, namely the front thighs of a pair of pants.

FIG. 2 shows a side exploded view of a section of the panel from FIG. 1. FIG. 3 shows a top view of a section of the face surface of a panel with a reservoir for fine particles.

(The foregoing figures are intended to illustrate inventive principles and are not necessarily intended to represent scaling accurately.)

DETAILED DESCRIPTION

Representative embodiments according to the inventive subject matter are shown in FIGs. 1- 3, wherein the same or generally similar features share common reference numerals.

Generally, the innovations are directed a three-dimensional knit spacer fabric constructs that are configured to hold fine particle such as chalk and selectively dispense the particles from a surface of the construct. The construct is especially suited for integration into articles of

manufacture, including garments, footwear, wearable packs and bags (e.g., backpacks, waist packs, tool belts, sling-packs, duffle bags, gym bags etc.); personal articles like towels and weight-lifting belts; and equipment, furnishings, stations, and fixtures at gyms or workplaces.

Chalk powder is an example of a powder that can be used with the innovations described herein. Powdered hand chalk for climbers, gymnasts, weight lifters is typically powdered magnesium carbonate as the principal component, alone or in blends with other particles. Calcium carbonate is another form of chalk that may serve as a hand chalk alone or in blends. Silicon dioxide is another powder that may be used alone or in blends in the innovative constructs.

Powdered rosin is another particulate substance that could be used with the innovative constructs.

An innovative construct may be in the form of a composite fabric panel that includes a first fabric layer or face layer 12, a second fabric or back layer 14, and a spacer or pile yam or yarns 16 that are inter-knitted or inter- woven with the first and second layers so as to interconnect the two layers and structural hold them in a spaced-apart arrangement. Accordingly, composite fabric construct may be referred to as having a three-dimensional (3D) structure.

As used herein, a yam or thread is any knittable or weavable, elongate filamentous structure, and yams, threads, and filaments are synonymous. In the innovative, three-dimensional knit fabric constmcts contemplated herein, the yams may include natural or synthetic material, such as polyester, polypropylene, acrylic, elastane, cotton, wool, or nylon, and any combination of blends. In any of the innovations contemplated herein, some or all the construct may be formed of a mono filament, multifilament, bi-component, spun, textured, crimped, twisted, and/or fully oriented yarn. Textured yarns may suitably help retain fine particles and/or help absorb moisture, among other attributes. Textured yarns are made of fully drawn filament fibers with a changed surface, shape and texture developed by using certain spinning techniques. Nylon and polyester are two main fibers that are textured, but other yam materials may also be textured. There are two main types of textured yarns: stretch yams and bulk yams. Stretch yam can be made by using any of the following methods: (1) by using special heat setting treatment to thermoplastic filament fibers such as nylon and polyester; (2) from elastomeric fibers; (3) from bi-component fibers; (4) from bi constituent fibers; and (5) from chemically treated natural fibers. Bulk Yarns are softer and much pliable than tightly constructed twisted yarns. Bulk yams also have a better cover. They create a less transparent fabrics and are of two types: high bulk yarns; and loop-bulk or airjet yarns

The resulting 3D fabric construct may be in whole or part selectively and varyingly elastic or inelastic based on use of elastic and/or inelastic yam materials or knit or woven structural schemes. The fabric may be constructed such that the bulk ratio of the stitch and pile yarns is controlled to provide desired properties discussed below.

Because of a construct’s 3D structure, the spacing of the first layer 12 from the second layer 14 defines a reservoir 13 for fine particles 2 between the first and second layers, with the particles being selectively released on a trigger event. The spacing of the first layer from the second layer in a static condition, unfilled with particles, may be at least lmm, 2mm, 3mm, 4mm, 5mm, 6mm,

7mm, 8mm, 9mm, lOmm, l lmm, l2mm, l3mm, l4mm, l5mm, l6mm, l7mm, l8mm, l9mm, 20mm, 25mm, 30mm, 35mm, 40mm, 45mm, 50mm, 55mm, 60mm, 65mm, 70mm, 75mm, 80mm, 90mm, lOOmm, l25mm, l50mm, l75mm, 200mm, 250mm, 300mm, 350mm, 400mm, 450mm, 500mm, 600mm, 700mm, 800mm, 900m or more. The spacing can be varied considerably depending on the volume of particles that are desired to be containable. In some, non-limiting, representative applications, the spacing can be between lmm and 900mm. In other applications, the spacing can be from lmm to 500mm, lmm to 250mm, 1- lOOmm, l-50mm, l-25mm. In other applications, the spacing is 3-l5mm, or 5-l2mm.

In some embodiments, the trigger event causing a controlled release of the fine particles in reservoir 13 is compression of construct 10 such that the first layer is displaced toward the second layer. For example, hand presses the layers together. By selection structural yams of appropriate length and material properties, the construct can be tuned so that the amount of powder dispensed is proportional to the force applied to the particles in the reservoir. For example, slightly pressing on the construct could slightly displace face layer 12, causing only a small quantity of particles to be dispensed through the pervious surface of layer 12. A firmer press would dispense more. Another trigger event could be forcing air against the particles. This could be based on hand slapping the construct, forcing air against the particles sufficient to displacement. Similarly, the reservoir could be fluidly coupled to a pump, fan or compressed air source that forces air or other fluid against the particles sufficient to displace them from the reservoir and through the pervious surface of layer 12.

FIG. 1 shows one possible embodiment of the innovations. Constructs in the form of panels 10 are disposed on the front thighs of a pair of pants 1. As discussed below, each panel may be in a unitary knit or woven construction with surrounding fabric areas, e.g., at least the surrounding thigh area of the pants.

First layer 12 is the face of the panel, namely the side the faces away from the user’s skin.

The second layer 14 in on the back of the panel, namely the side that faces the users’ skin 3. The panels include reservoir 13 between the face layer 12 and back layer 14. As indicated, for example, when a user initiates a trigger event, fine particles 2 disposed in the reservoir exit through a particle- pervious surface of the face layer 12. The particles may be released as a fine dispersion and onto the hand(s) of the user.

The face layer may be a mesh structure, with mesh openings 15 that are sufficiently large enough to allow the particles to dispense from a retained condition in the reservoir. The The mesh may be made of yarns or threads having deniers of 1 denier (D) to 600D or more. The mesh acts to sieve particles. The proper opening size can be empirically matched to particle sizes. Particles can have a range of sizes from sub-micron nanoparticles to particles of lmm or over. The following table represents possible mesh attributes for particles in the 25-l068um range.

The openings in the mesh are configured to allow passage of particles in a spray-like, puff, or dusting manner under a trigger event. The mesh can openings be configured in a great variety of shapes so long as this purpose is achieved. Construction of 3D fabrics with a mesh layer is known. See, for example, W02006100434, entitled, Improvements In or Relating To Spacer Fabrics , which is hereby incorporated by reference in its entirety for all purposes.

While the mesh openings may have uniform size and may be distributed uniformly over a panel, they may also be varied in size and may be integrated with non-mesh fabric zones over a panel. Such variations could still allow for dispensation of fine particles for an intended application.

The first layer 12 of construct 10 need not be a mesh fabric. It could be a knit or woven fabric with a sufficiently open knit or woven structure to be pervious to particles in the reservoir.

In typical applications, since face layer 12 is exposed at the surface of a garment or other object, it should have an overall durable or wear resistant construction, depending on intended application. For example, higher denier or tenacity yarns may be used in the layer when it is integrated into footwear or garments.

Other zones or features that may be incorporated into or with the mesh include an optional reinforcement yarns or other filaments 17 (FIG. 2) that provide a ripstop construction. Suitable ripstop include grids of relatively high denier or high tenacity filaments. A zone 19 (FIG. 3) providing elasticity, strength, or another material property different from the base mesh fabric could also be integrated with the mesh fabric. For example, zone 19 could include elastane-based yarns that provide a stretch zone.

The face layer may also be made of relatively high denier yarns such that the user can wipe his or her hands across the surface and remove dirt and debris by ablative contact with thicker yarns that project or rough up the fabric surface. For example, yams of at least 40, 50, 70, 80, 90, 100, 200, 300, 400, 500, 600, 700, 800, 900 denier in a mesh fabric could serve this purpose.

Alternatively, or additionally, relatively larger filaments 17 in base fabric made of relatively smaller filaments could provide a rougher surface for engaging dirt or debris on a user’s hand.

The second or back layer 14 need not be pervious to the fine particles. It would typically be a relatively impervious barrier layer that retains the particles under normal use, including during a trigger event that preferentially releases particles from the first or face layer 12. It could also be a relatively softer, less wear resistant fabric than the face layer fabric. The back layer may also be a comfort layer that goes against the user’s skin. For cold weather applications, the layer could be insulative and/or waterproof or water resistant.

It some embodiments suitable for use in garments, including pants and shirts, or other lower and upper body coverings, the back layer 14 includes hydrophobic yarns sufficient to render the back layer overall hydrophobic. The face layer includes hydrophilic yams that render the face layer overall hydrophilic. The spacer yarns 16 are overall hydrophobic. The hydrophobic areas wick moisture away from the user’s body to the face layer where evaporation can more efficiently occur. This construction promotes cooling and drying of the garment during use. The moisture absorbing, hydrophilic face layer also absorbs moisture from the user’s hand when the user wipes his or her hand on the face layer, allowing for moisture removal while chalk is simultaneously applied. This scheme allows for more effective application of chalk.

Fabrics according to the innovations may be prepared by known techniques for producing a 3D spacer fabric.

Knit Constructs

Among those are production on a double-needle bar warp knitting machine, weft knitting machines, dial and cylinder machines, v-bed machines, and warp knitting machines (e.g., Rashcel knitting machines).

Woven Constructs

For woven embodiments, the 3D woven fabric construct is a variant of the 2D weaving process, and it is an extension of the very old technique of creating double and triple woven cloth. 3D weaving allows the production of fabrics up to 10 cm in thickness. Fibers placed in the thickness direction are called z-yarn, warp weaver, or binder yarn for 3D woven fabrics. More than one layer of fabric is woven at the same time, and z-yam interlaces warp and woof yams of different layers during the process. At the end of the weaving process, an integrated 3D woven structure, which has a considerable thickness, is produced.

By using jacquard woven techniques such as bifurcation, the 3D woven constructs can be created with varying structures, zones, and properties

There are several types of 3D woven fabrics that are commercially available; they can be classified according to their weaving technique. 3D woven interlock fabrics, are 3D woven fabrics produced on a traditional 2D weaving loom, using proper weave design and techniques, it could either have the weaver/z-yarn going through all the thickness of the fabric or from layer to layer. 3D orthogonal woven fabrics, are 3D woven fabrics produced on a special 3D weaving loom. The architecture of the 3D orthogonal woven fabric consists of three different sets of yams; warp yams (y-yarn), weft yarns (x-yam), and (z-yarn). Z-yarn is placed in the through-thickness direction of the constmct. In 3D orthogonal woven fabric there is no interlacing between warp and weft yams and they are straight and perpendicular to each other. On the other hand, z-yarns combine the warp and the weft layers by interlacing (moving up and down) along the y-direction over the weft yarn.

Interlacing occurs on the top and the bottom surface of the fabric. (Source for above discussion on wovens: https ://en. wikipedia.org/wiki/3D composite )

For purposes of discussion, the innovations will be discussed in terms of a knit constmct hereafter, but as indicated, woven constmcts may also be possible.

In a three-dimensional knit spacer fabric 10, first layer 12 may be made from a first stitch yarn, a second fabric layer 14 may be made from a second stitch yarn. Stmctural pile yarns 16 stmcturally interconnect the two layers so that they are maintained as a composite fabric under normal use. The average length of the structural pile yarns may be at least lmm, 2mm, 3mm, 4mm, 5mm, 6mm, 7mm, 8mm, 9mm, lOmm, l lmm, l2mm, l3mm, l4mm, l5mm, l6mm, l7mm, l8mm, l9mm, 20mm, 25mm, 30mm, 35mm, 40mm, 45mm, 50mm, 55mm, 60mm, 65mm, 70mm, 75mm, 80mm, 90mm, lOOmm, l25mm, l50mm, 175mm, 200mm, 250mm, 300mm, 350mm, 400mm, 450mm, 500mm, 600mm, 700mm, 800mm, 900m or more. The average length can be varied considerably depending on the volume of particles that are desired to be containable. In some, non limiting, representative applications, the length can be between lmm and 900mm. In other applications, the length can be from lmm to 500mm, lmm to 250mm, l-lOOmm, l-50mm, l-25mm. In other applications, the length is 3-l5mm, or 5-l2mm

The average denier of the structural pile yarns may be at least 40, 50, 70, 80, 90, 100, 200,

300, 400, 500, 600, 700, 800, 900. Adequate densities of the yarns may be empirically determined to achieve a desired degree of resistance to displacement of the first and second layers and thereby control the release of powder on a trigger event. For example, lower density yarns will achieve easier displacement and release.

Under static conditions, the structural pile yarns are configured to maintain a separation between the first and second layers so that the reservoir 13 is defined. The pile yams may be resilient such that they can compress, bend and/or flex when the first layer is displaced towards the second layer, or vice versa. They may also have elasticity to allow for the displacement of the layers away from each other, which could allow for increased reservoir volume.

Following removal of a displacement force, the resilient yams, which have been placed under load, apply a return force on the layers, returning them to the same or substantially the same degree of separation they had under the static condition.

As seen in FIG. 2, additional, particle retention pile yams 18 may be disposed in the stmcture. These are generally yarns of a finer and denser nature than the stmctural yarns. They extend from one of both inner surfaces of the first and second layers. In the embodiment of FIG. 2, they are shown extending part way into the space of the reservoir from the back (bottom)layer 14. They are structurally part of the back layer and provide a nap-like surface. The retention pile yams can interact with particles, particularly fine particles, such that they engage the particles and stabilize their location in the reservoir. The engagement is sufficiently loose such that the trigger event will cause the particles to disperse. The engagement may be by mechanical interference and/or light chemical bonding, such as Van der Waals forces, electrostatic bonding, and non-polar interactions. Accordingly, persons skilled in the art can correspond retention pile thread sizes and densities and materials to specific particle sizes and types to stabilize the particles, while allowing for dispensation on a trigger event.

The average length of the retention pile yarns may be the same or less than the structural pile yarns. However, they could also be longer and folded over. In some embodiments, they have a length that is no more than 100%, 90%, 80%, 70%, 60%, 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, or 10% of the height of the reservoir or length of the structural pile yams.

The average denier of the particle retention yarns may be no greater than 200D, 150D, 100D, 90D, 80D, 70D, 60D, 50D, 40D, 30D, 20D, 10D, 9D, 8D, 7D, 6D, 5D, 4D, 3D, 2D or 1D. The average denier of the particle retention pile yarns may be between 100D and 1D, or 50D and 1D, or 40D and 1D, or 30D and 1D, or 20D and 1D, or 10D and 1D. Adequate densities of the yams may be empirically determined to achieve a desired release of powder on a trigger event. For example, lower density will result in fewer engagements with the retention yarns and easier release.

As indicated above, the structural yarn interconnecting the two layers of the innovative three-dimensional spacer fabric should have sufficient resilience and stiffness to keep the two fabric layers apart even if pressure is applied to any one of the fabric layers. In construction, the

interconnecting pile yarns may be made of either the same or different material than that of the two fabric layers. Particularly, to render the interconnecting pile yarn resilient, the yarn may be made of a resilient material such as monofilament or multifilament polyester, nylon, etc. The retention yarns may be of similar materials or construction but would typically be of lower deniers and have a higher density in the 3D fabric construct.

The panel 10 may be loaded and reloaded with chalk or other fine particles by providing an sealable slot or other aperture (not shown) along an edge or body portion of the panel. The slot is opened to add particles and sealed thereafter. Sealable slots may be open and closed by zippers, Velcro™ fasteners, zip-lock structures, etc. Some mechanical agitation of the panel, like shaking or pressing, may be needed to move the particles into the reservoir. In another embodiment, no loading aperture is used. Instead, particles are spread onto the surface of the face layer of the panel and pressed through the face layer into the reservoir.

Unitary Knit Construction

A knit element may be formed from at least one yarn that is manipulated (e.g., with a knitting machine) to form a plurality of intermeshed loops that define a variety of courses and wales. As used herein, a“unitary knit construction” when formed as a one-piece element through a knitting process. That is, the knitting process substantially forms the various features and structures of a construct without the need for significant additional manufacturing steps or processes. A unitary knit construction may be used to form a knitted construct having structures or elements that include one or more courses of yarn or other knit material that are joined such that the structures or elements include at least one course in common (i.e., sharing a common yam) and/or include courses that are substantially continuous between each of the structures or elements. With this arrangement, a one- piece element of unitary knit construction is provided.

In various embodiments, a knitted component may incorporate various types of yarn that impart different properties to separate areas of the upper. For example, one area of a construct 10 may be formed from a first type of yam that imparts a first set of properties, and another area of constmct 10 may be formed from a second type of yam that imparts a second set of properties. In this configuration, properties may vary throughout the constmct by selecting specific yams for different areas of construct. Similarly, construct 10 could be a sub area in a larger unitary, knit construct. For example, construct 10 could be integrated in a unitary knit construction with some or all of another knit fabric construct, e.g., at least the front thigh panels of pants 1 (FIG.l).

(A unitary woven construction means a similar intermeshing of woven yarns into a unitary structure.)

The properties that a yarn will impart to an area of a knitted component partially depend upon the materials that form the various filaments and fibers within the yarn. Cotton, for example, provides a soft hand, natural aesthetics, and biodegradability. Elastane and stretch polyester each provide substantial stretch and recovery, with stretch polyester also providing recyclability. Rayon provides high luster and moisture absorption. Wool also provides high moisture absorption, in addition to insulating properties and biodegradability. Nylon is a durable and abrasion-resistant material with relatively high strength. Polyester is a hydrophobic material that also provides relatively high durability.

In addition to materials, other aspects of the yams selected for a knitted component may affect the properties of the construct. For example, a yam forming construct 10 may be a monofilament yarn, a bicomponent yarn, or a multifilament yam. The yam may also include separate filaments that are each formed of different materials. In addition, the yarn may include filaments that are each formed of two or more different materials, such as a bi-component yam with filaments having a sheath-core configuration or two halves formed of different materials. Different degrees of twist and crimping, as well as different deniers, may also affect the properties of the constmct. Accordingly, both the materials forming the yarn and other aspects of the yarn may be selected to impart a variety of properties to separate areas of a unitary knit constmct.

Persons skilled in the art will recognize that many modifications and variations are possible in the details, materials, and arrangements of the parts and actions which have been described and illustrated to explain the nature of the inventive subject matter, and that such modifications and variations do not depart from the spirit and scope of the teachings and claims contained therein.

Any patent and non-patent literature cited herein is hereby incorporated by references in its entirety for all purposes.

The principles described above about any particular example can be combined with the principles described regarding any one or more of the other examples. The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the disclosed innovations. Various modifications to those embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of this disclosure. Thus, the claimed inventions are not intended to be limited to the embodiments shown herein, but are to be accorded the full scope consistent with the language of the claims, wherein reference to an element in the singular, such as by use of the article "a" or "an" is not intended to mean "one and only one" unless specifically so stated, but rather "one or more". As used herein,“and/or” means“and” or "or", as well as“and” and “or.”

All structural and functional equivalents to the elements of the various embodiments described throughout the disclosure that are known or later come to be known to those of ordinary skill in the art are intended to be encompassed by the features described and claimed herein.

Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims.

The inventors reserve the right to claim, without limitation, at least the following subject matter.