Tubular knit fabric and system

• US 6,941,775 B2
• Filed: 04/07/2003
• Issued: 09/13/2005
• Est. Priority Date: 04/05/2002
• Status: Active Grant

• Current Assignee: Electronic Textile Incorporated, MMI-IPCO LLC
• Original Assignee: Electronic Textile Incorporated
• Inventors: Sharma, Vikram
• Primary Examiner(s): WORRELL JR, LARRY D
• Application Number:
  US10/408,641
• Publication Number:
  US 20030224685A1
• Time in Patent Office: 890 Days
• Field of Search: 662/02, 661/69.R, 66170-171, 661/72.E, 66175-177, 66194-198, 600/388, 600390-391, 290/2, 290/5, 210/2
• US Class Current: 66/202
• CPC Class Codes: A41D 1/005 with embedded cable or connector
• CPC Class Codes: A41D 13/1281 with incorporated means for medical monitoring
• CPC Class Codes: A41D 2500/10 Knitted
• CPC Class Codes: D04B 1/123 with laid-in unlooped yarn, e.g. fleece fabrics with elastic weft yarn D04B1/18
• CPC Class Codes: D04B 1/14 Other fabrics or articles characterised primarily by the use of particular thread materials
• CPC Class Codes: D04B 1/24 wearing apparel
• CPC Class Codes: D10B 2401/18 including electronic components
• CPC Class Codes: D10B 2403/0114 with one or more yarns appearing predominantly on one face, e.g. plated or paralleled yarns for pile fabrics D03D27/00, D04B1/02, D04B21/02; for intarsia fabrics D04B1/126
• CPC Class Codes: D10B 2403/02431 with electronic components, e.g. sensors or switches
• CPC Class Codes: Y10S 2/902 Antistatic
• CPC Class Codes: Y10T 442/40 Knit fabric [i.e., knit strand or strip material]

Abstract

A tubular knit fabric comprising at least one insulative yarn, at least one stretchable yarn, and at least one functional yarn, the insulating yarn, the stretchable yarn, and the functional yarn knitted together to define a tubular fabric sleeve having the functional yarn embedded in the tubular fabric sleeve in a continuous spiral configuration which longitudinally extends the length of the sleeve.

Claims

1. A tubular knit fabric comprising:

at least one insulative yarn;

at least one stretchable yarn; and

at least one functional yarn, said insulating yarn, said stretchable yarn, and said functional yarn knitted together to define a tubular fabric sleeve having the functional yarn embedded in said tubular fabric sleeve in a continuous spiral configuration which longitudinally extends the length of said sleeve.

2. The tubular knit fabric of claim 1 wherein said functional yarn is an electrically conductive yarn.

3. The tubular knit fabric of claim 1 wherein said conductive yarn is made of a material chosen from the group consisting of:

stainless steel, copper, alloy, copper plated with silver, core clad, a kevlar core, a filament core coated with silver, and conductive polymer.

4. The tubular knit fabric of claim 3 wherein said conductive yarn has an electrical resistance of 0.01 ohm/meter to 5,000 ohm/meter.

5. The tubular knit fabric of claim 1 wherein said insulative yarn is made of synthetic fibers and/or natural fibers and/or regenerated fibers made of a material chosen from the group consisting of:

polyester, nylon, wool, rayon, cotton, silk, linen, polypropylene and acrylic.

6. The tubular knit fabric of claim 1 wherein said stretchable yarn is made of a material chosen from the group consisting of:

spandex, and elastomeric yarn.

7. The tubular knit fabric of claim 1 in which said fabric stretches longitudinally and radially.

8. The tubular knit fabric of claim 1 in which said fabric is used to manufacture a garment.

9. The tubular knit fabric of claim 8 in which said garment is seamless.

10. The tubular knit fabric of claim 9 in which said functional yarn is spaced in a predetermined spacing in a predetermined section of said garment.

11. The tubular knit fabric of claim 8 in which said garment is chosen from the group consisting of:

shirt, pants, jacket, bra, underwear, sock, stocking, knee brace, and/or arm brace, and/or leg brace.

12. The tubular knit fabric of claim 9 in which said garment is chosen from the group consisting of:

shirt, pants, jacket, bra, underwear, sock, stocking, knee brace, and/or arm brace, and/or leg brace.

13. The tubular knit fabric of claim 1 further including a plurality of insulative yarns, a plurality of said stretchable yarns, and a plurality of said functional yarns.

14. The tubular knit fabric of claim 10 wherein said plurality of insulative yarns, said plurality of stretchable yarns, and said plurality of conductive yarns are knitted together in a repeating pattern to define said tubular fabric sleeve, said pattern including at least one functional yarn per pattern.

15. The tubular knit fabric of claim 14 wherein said plurality of insulative yarns, said plurality of stretchable yarns, and said plurality of conductive yarns are knitted together in a plated knit construction on at least one side of said tubular knit fabric.

16. The tubular knit fabric of claim 14 wherein said plurality of insulative yarns, said plurality of stretchable yarns, and said plurality of conductive yarns are knitted together in a plated knitted construction on both sides of the fabric, said fabric having an insulated yarn in between the stretchable yarn and the conductive yarn.

17. The tubular knit fabric of claim 15 wherein said plated knit construction is chosen from the group consisting of:

single jersey, double-knit and ribs.

18. The tubular knit fabric of claim 1 wherein said tubular fabric sleeve is body sized.

19. The tubular knit fabric of claim 14 wherein said tubular fabric sleeve is body sized.

20. The tubular knit fabric of claim 14 wherein said pattern is a symmetric pattern of said plurality of insulative yarns, stretchable yarns and functional yarns.

21. The tubular knit fabric of claim 14 wherein said pattern is an asymmetric pattern of said plurality of insulative yarns, stretchable yarns and functional yarns.

22. The tubular knit fabric of claim 14 wherein said plurality of said functional yarns are electrically conductive yarns.

23. The tubular knit fabric of claim 11 wherein the said tubular fabric sleeve is radially cut to form a narrow band of tubular fabric.

24. The tubular knit fabric of claim 23 in which said narrow band of tubular fabric is attached to a garment.

25. The tubular knit fabric of claim 24 in which said garment is chosen from the group consisting of:

a bra, running pants, shirts, underwear, socks, a hat, gloves, stocking, orthopedic support braces for the arms and legs.

26. The tubular knit fabric of claim 9 in which said seamless garment is knitted on a seamless knitting machine.

27. The tubular knit fabric of claim 1 wherein said functional yarn is used to transmit signals.

28. The tubular knit fabric of claim 1 wherein said functional yarn is used as a power pathway.

29. The tubular knit fabric of claim 2 wherein said electrically conductive yarn is used for generating heat.

30. The tubular knit fabric of claim 1 wherein said functional yarn is for thermo-electric cooling.

31. The tubular knit fabric of claim 1 wherein said functional yarn is a rechargeable battery.

32. A tubular knit fabric system, the system comprising:

at least one insulative yarn;

at least one stretchable yarn;

at least one conductive yarn, said insulating yarn, said stretchable yarn, and said conductive yarn knitted together to define a tubular fabric sleeve having the conductive yarn embedded in said tubular fabric sleeve in a continuous spiral configuration which longitudinally extends the length of said sleeve; and

a device connected to said conductive yarn.

33. The system of claim 32 in which said device is a sensor for measuring physiological signs of the body.

34. The system of claim 32 in which said physiological signs measured are chosen from the group consisting of:

heart rate, blood pressure, heart abnormalities, sweat rate, basal metabolic rate and temperature.

35. The system of claim 32 in which said sensor is a conductive electrode and/or an electrical circuit.

36. The system of claim 32 in which sensor is a conductive patch made of a material chosen from the group consisting of:

resin, resin with embedded conductive particles, metal, copper, alloys, conductive rubber, and conductive epoxies.

37. The system of claim 32 in which said device connected to said conductive yarn is chosen from the group consisting of:

a heart rate measuring device, a blood pressure measuring device, a temperature measurement device, a sweat measurement device, and a basal metabolic measuring device, an activity measurement device, a hydration measurement device, and a congnitivity measuring device.

38. The system of claim 32 further including terminals connected at the end and/or opposite ends of said conductive yarn.

39. The system of claim 38 in which an electronic unit is connected to said terminals, said electronic unit communicating to said device connected to said conductive yarn.

40. The system of claim 38 in which said electronic unit connected to said terminal is chosen from the group consisting of:

a heart rate measuring device, a blood pressure measuring device, a temperature measurement device, a sweat measurement device, and a basal metabolic measuring device, an activity measurement device, a hydration measurement device, and a congnitivity measuring device, said electric unit connected to a garment by conductive rubber and/or sewing and/or mechanical snaps, and/or conductive epoxy or combination thereof.

41. The system of claim 32 further including a plurality of devices connected to said conductive yarn.

42. The system of claim 32 further including a plurality of devices connected to a plurality of conductive yarns.

43. The system of claim 32 in which one of said plurality of sensors is located on the right side of a garment and another of each said plurality of sensors is located on the left side of a garment for heart rate monitoring.

44. The system of claim 41 in which one of said plurality of sensors is located on the top of a garment and another of each said plurality of sensors is located on the bottom of a garment.

45. The system of claim 42 in which one of said plurality of sensors is located on the right side of a garment and another of each said plurality of sensors is located on the left side of a garment.

46. The system of claim 42 in which one of said plurality of sensors is located on the top left side of a garment and another of each said plurality of sensors is located on the bottom right side of a garment.

47. The system of claim 43 in which said garment is chosen from the group consisting of:

a bra, running pants, shirt, underwear and socks, a hat, gloves, orthopedic brace, stocking and swimsuits.

48. The system of claim 44 in which said garment is chosen from the group consisting of:

a bra, running pants, shirt, underwear and socks, a hat, gloves, orthopedic brace, stocking and swimsuits.

49. The system of claim 45 in which said garment is chosen from the group consisting of:

a bra, running pants, shirt, underwear and socks, a hat, gloves, orthopedic braces, sleeves, swimsuits and stockings.

50. The system of claim 46 in which said garment is chosen from the group consisting of:

a bra, running pants, shirt, underwear and socks, a hat, gloves, orthopedic braces, sleeves, swimsuits and stockings.

51. The system of claim 32 in which said system is incorporated into a garment chosen from the group consisting of:

a bra, running pants, shirt, underwear and socks, a hat, gloves, orthopedic braces, sleeves, swimsuits and stockings.

52. The system of claim 32 wherein said tubular fabric sleeve having said conductive yarn embedded in said tubular fabric sleeve in a continuous spiral configuration which longitudinally extends the length of said sleeve, is radially cut and orientated in said garment such that the continuous spiral configuration extends vertically along the length of the garment.

53. An integrated data and power bus comprising:

at least one insulative yarn;

at least one stretchable yarn; and

at least one functional yarn, said insulating yarn, said stretchable yarn, and said functional yarn knitted together to define a tubular fabric sleeve having said functional yarn embedded in said tubular fabric sleeve in a continuous spiral configuration which longitudinally extends the length of said sleeve.

54. A tubular knit fabric comprising:

at least one insulative yarn;

at least one stretchable yarn; and

at least one functional yarn, said insulating yarn, said stretchable yarn, and said functional yarn knitted together to define a tubular fabric sleeve, having the functional yarn embedded said tubular fabric sleeve in a continuous spiral configuration which longitudinally extends the length of said sleeve;

said tubular fabric sleeve radially cut and orientated such that the continuous spiral configuration extends vertically along the length of a garment.

55. A tubular knit fabric comprising:

at least one insulative yarn;

at least one stretchable yarn; and

at least one functional yarn, said insulating yarn, said stretchable yarn, and said functional yarn knitted together in a plated knit construction to define a tubular fabric sleeve having the functional yarn embedded in said tubular fabric sleeve in a continuous spiral configuration which longitudinally extends the length of said sleeve.

56. A tubular knit fabric comprising:

at least one insulative yarn;

at least one stretchable yarn; and

at least one functional yarn, said insulating yarn, said stretchable yarn, and said functional yarn knitted together in a plated knit construction to define a seamless tubular fabric sleeve having the functional yarn embedded in said tubular fabric sleeve in a continuous spiral configuration which longitudinally extends the length of said seamless tubular fabric sleeve.

57. A method for manufacturing a tubular knit fabric, the method comprising:

providing at least one insulative yarn;

providing at least one stretchable yarn;

providing at least one functional yarn; and

knitting said insulative yarn, said stretchable yarn and said functional yarn together to define a tubular fabric sleeve having the functional yarn embedded in said tubular fabric sleeve in a continuous spiral configuration which longitudinally extends the length of said sleeve.