WO2025107258A1

WO2025107258A1 - Warp knitted spacer fabric

Info

Publication number: WO2025107258A1
Application number: PCT/CN2023/133790
Authority: WO
Inventors: Yu Chen
Original assignee: Lear Corp
Current assignee: Lear Corp
Priority date: 2023-11-23
Filing date: 2023-11-23
Publication date: 2025-05-30
Anticipated expiration: 2026-05-23

Abstract

A spacer fabric comprises a first knit layer, a second knit layer, and spacer yarns extending between and connecting the first and second knit layers. The first knit layer may include a mesh structure comprising a plurality of spaced openings separated by a plurality of plain fabric sections. The second knit layer may include a plain structure, and the first knit layer may comprise a series of at least two threads separated by a void of at least two threads. The spacer yarns may comprise about 95%polyethylene terephthalate, and/or the spacer yarns may comprise about 95%recycled plastic. The first knit layer may include a plurality of spaced openings disposed in an offset configuration.

Description

WARP KNITTED SPACER FABRIC

TECHNICAL FIELD

The present disclosure generally relates to warp knitted spacer fabrics including one or more warp knit mesh layers. At least one or more other embodiments relate to a warp knitted 3D spacer mesh fabric, and include a manufacturing process for warp knitted 3D fabrics with high permeability and high resilience.

BRIEF DESCRIPTION OF THE DRAWINGS

While the claims are not limited to a specific illustration, an appreciation of various aspects may be gained through a discussion of various examples. The drawings are not necessarily to scale, and certain features may be exaggerated or hidden to better illustrate and explain an innovative aspect of an example. Further, the exemplary illustrations described herein are not exhaustive or otherwise limiting, and embodiments are not restricted to the precise form and configuration shown in the drawings or disclosed in the following detailed description. Exemplary illustrations are described in detail by referring to the drawings as follows:

FIG. 1 is a perspective view of an embodiment of a spacer fabric showing details of the layers of the spacer fabric according to teachings of the present disclosure.

FIG. 2 is a variety of photographs of embodiments of the layers of a spacer fabric according to teachings of the present disclosure.

FIG. 3 is a photograph at 10X magnification of an embodiment of the second layer mesh fabric according to teachings of the present disclosure.

FIG. 4 is a photograph at 10X magnification of an embodiment of the first layer mesh fabric according to teachings of the present disclosure.

FIG. 5 is a schematic digital picture of an embodiment of the first layer mesh fabric according to teachings of the present disclosure.

FIGS. 6A and 6B are illustrations of a yarn movement chart showing the movement of the yarn in the first layer of the fabric according to teachings of the present disclosure.

FIG. 7 is an illustration of the first layer yarn movements of an embodiment of the fabric according to teachings of the present disclosure.

FIG. 8 is an illustration of the first layer yarn movements of an embodiment of the fabric according to teachings of the present disclosure.

FIG. 9 is a photograph at 10X magnification of an embodiment of the second layer according to teachings of the present disclosure.

FIG. 10 is an illustration of a single yarn movement chart showing the movement of yarn in the second layer according to teachings of the present disclosure.

FIG. 11 is an illustration of the second layer yarn movements of an embodiment of the second layer of the fabric according to teachings of the present disclosure.

FIG. 12 generally illustrates a warp knitting representation of a 3D spacer mesh fabric and system according to teachings of the present disclosure.

DETAILED DESCRIPTION

As required, detailed embodiments of the present disclosure are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the disclosure that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present disclosure.

With reference to Figures 1 and 2, a representative a spacer fabric (e.g., layer) 10 of the present disclosure is illustrated. The spacer fabric 10 could be used in a variety of applications. In certain embodiments, the spacer fabric 10 could be used as a seat cushion layer, either with or without a corresponding foam layer, such as a layer of polyurethane foam. The spacer fabric 10 could be used as a cushion, or cushion component in any cushion application, such as a seat bottom a seatback, and/or a trim panel.

In other embodiments, the spacer fabric 10 could be used as a trim layer component, wherein the spacer fabric 10 is secured below a trim layer. In such an embodiment, any suitable trim layer could be used, such as, but not limited to, leather, synthetic leather, plastics, such as vinyl, polyurethane, and fabric layers. The trim layer, or decorative layer, can be secured to the spacer fabric 10 by any suitable technique, such as by stitching or adhesive, for instance.

In other embodiments, the spacer fabric 10 can be used as a composite material requiring some level or elasticity and/or breathability. It should readily be understood that the composites made with a spacer fabric 10 of the present disclosure could be other automotive or non-automotive composites.

As illustrated schematically in Figures 1-3, the spacer fabric 10 can include a mesh first knit layer 12, a generally solid or closed, (i.e., plain) second knit layer 14 and spacer yarns 16 extending between and connecting the first and second knit layers 12 and 14.

In certain other embodiments, spacer fabric 10 may comprise a warp knitted 3D mesh fabric having a warp knitted mesh fabric upper layer 12, a warp knitted fabric (without mesh) lower knit layer 14, and monofilaments 16 knitted into the first knit layer 12 and second knit layer 14 to form an integral three-dimensional network structure 10.

In certain other embodiments, and as will be described in more detail below, the spacer fabric 10 of the present disclosure has relatively high air permeability, elasticity and support compared to other fabrics, and it has the characteristics of the mesh surface that is soft and the flat surface that is stiff. In this regard, the spacer fabric 10 of the present disclosure, is particularly suitable for use in the lower cushion material of automobile seat cushion. In at least certain embodiments, the mesh forming the first knit layer 12 and the plain cloth forming the second knit layer 14 may have unique structures, which are representatively shown in the Figures.

In certain embodiments, the two knit layers 12 and 14 have stitch wales that run in the production direction and stitch courses that run in the transverse direction. The spacer yarns 16 that extend between and connect the first and second knit layers 12 and 14 can be any suitable monofilament yarn.

In certain other embodiments, the first knit layer 12 and the second knit layer 14 are made of common multi strand polyester filament. In at least one embodiment, the first knit layer 12 and the second knit layer 14 are made of common multi strand polyester filament having a size 55-167dtex, and the middle connection monofilament 16 having a size 33 -56 dtex/1F. It should be understood that other sizes and or types of yarn can be used and still be consistent with the present disclosure.

In at least certain other embodiments, the interlayered yarn 16 should have good stiffness and resilience. In certain other embodiments, the size and thickness of monofilament can be selected depending upon the desired compression strength and spring back deformation characteristics desired to be achieved. In at least still certain other embodiments, the size of monofilament yarns 16 is 33-56dtex. It should be understood that other sizes and or types of monofilaments can be used and still be consistent with the present disclosure.

As best seen in Figures 4-5, the first knit layer 12 may include openings 8. In at least certain embodiments, the openings the first knit layer 12 are shown to be generally oval in shape, however the openings 8 can be any suitable shape such as elongated, circular, square and/or rectangular, to name a few. The size of the opening 8 on the first knit layer 12 can be adapted to any suitable size as require. Usually, the larger the opening 8, the better the air volume, however, the support will lessen with the increase of size of the opening 8.

An image of an exemplary embodiment of the first knit layer 12 is shown in Figures 5. As can be seen in the Figures, the first knit layer 12 can include an open mesh structure. As representatively shown in the illustrated embodiments, the open mesh structure of the first knit layer 12 may include a plurality of strips 6 of fabric broken up with a plurality of spaced openings 8.

In at least the illustrated embodiments, the openings 8 may be generally oval and extend in off set and staggered rows. In at least one embodiment, the openings 8 may be spaced in staggered rows. In at least one embodiment, the openings 8 may be spaced 0.5 to 20 mm, on center, in the width direction and are spaced 0.5 to 20 mm, on center, in the length direction.

As schematically shown in one embodiment in Figs. 3 and 12, the spacer fabric 10 can be produced by a warp knitted double needle bar machine. As schematically and representatively illustrated, six pattern bars L1, L2, L3, L4, L5 and L6 can be used to direct the yarn Y1, Y2, Y3, Y4, Y5 and Y6 to the needles 31 and 33. The pattern bars L1 and L2 can be used to direct yarn Y1 and Y2 to the needles 31 for knitting the first knit layer 12 (e.g., of mesh fabric) . The pattern bars L3 and L4 can be used to direct the yarn Y3 and Y4 to the needles 31 and 33 for knitting the support monofilament 16. The pattern bars L5 and L6 can be used to direct the yarn Y5 and Y6 to the needles 33 for knitting the underlay fabric 14.

The first knit layer 12 can include an open mesh structure, as schematically shown in Figs. 4 and 12. Figures 6A and 6B show an embodiments of a suitable single yarn pad yarn movement chart of two pattern bars. The motion diagram of padding yarn can be a coil formed by a needle from bottom to top. The horizontal dot column is used to represent the needles arranged on the needle bed in turn. The top of point 22 represents the front of the needle hook and the bottom of point 22 represents the back of the needle. The yarn Y1 swings through the pattern bar L1 to complete the needle 31 hook pad yarn and the needle 31 back traverse. The motion law is shown in the motion curve of yarn Y1 and Y2 in figures 6A and 6B. In the same way, yarn Y2 completes the above padding motion through pattern bar L2.

As representatively shown in Figures 6A and 6B, for the first knit layer 12 of fabric pad yarn movement diagram, the motion diagram of pad yarn shows the coil formed by needle in turn with dot (as shown in 22) lines from bottom to top. Points in the transverse direction are used to represent the needles (N1/N2/N3/N4/N5……) arranged in turn, with the upper part of the point 22 indicating the front of the needle hook, and the lower part of the point 22 indicates the back of the needle. The continuous line segment is used to represent the movement of the yarn guide needle of the pattern bar in front of the needle and at the back of the needle. Generally, the numbering (digitization) of padding is 0, 1, 2, 3, 4, 5. . . from right to left in order between needles and is used to represent the motion track of the pattern bar. C1 --C17......denotes the row C formed by looping the yarn from the bottom to the top. The arrow 51, etc. indicates the movement direction of the yarn Y1 guiding through the pattern bar L1. The motion law of all the yarns on the pattern bar L1 is the same, and yarn Y1 is at least the illustrated embodiment, however it should be understood that other motion laws could be employed. In the illustrated embodiment, the stitch formation of one of the pattern bars L1 is recorded as: 1-0/2-3/1-0/2-3/1-0/2-3/4-5/3-2/4-5/3-2/4-5/3-2//, in Figure 6, where “1-0” corresponds to 39 in the C1 course, “2-3” corresponds to 40 in the C2 course where “1-0” corresponds to 41 in the C3 course, “2- 3” corresponds to 42 in the C4 course, “1-0” corresponds to 43 in the C5 course, “2-3” corresponds to 44 in the C6 course , where “4-5” corresponds to 45 in the C7 course, “3-2” corresponds to 46 in the C8 course, “4-5” corresponds to 47 in the C9 course, “3-2” corresponds to 48 in the C10 course , “4-5” corresponds to 49 in the C11 course, “3-2” corresponds to 50 in the C12 course, . The movement of the yarn cushion of pattern bar L2 may be completely symmetrical with that of pattern bar L1. The pad yarn of pattern bar L2 is recorded in the illustrated embodiment as: 4-5/3-2/4-5/3-2/4-5/3-2/1-0/2-3/1-0/2-3/1-0/2-3//. The numbers represent the mesh stitch formations of one of the bars with both bars working together to create the mesh pattern. In addition, the principal explanation of all the following motion diagrams of padding is the same as that in this paragraph, with the only difference being the motion law of padding.

Turning back to the embodiment illustrated in Figure 3, the mesh surface of the first knit layer 12 can include half the number of warp pieces compared to second surface of second knit layer 14, and as such, a lower density can result in a softer fabric. Further, the surface area between the mesh holes can be greater than about 35%of the overall mesh surface to ensure sufficient surface can be available for lamination to a trim material. The result can be less permanent deformation and/or less thickness loss from the lamination process.

As shown in Figure 6B, the long floating line 54 between 40 and 41 (e.g., the yarn traversing over an additional needle, instead of an adjacent needle) can provide greater flexibility when subjected to external force compression, and/or can cause the softness of the fabric to increase.

The first knit layer 12 can include an open mesh structure, as shown in the embodiment illustrated in Figures 4, 7 and 8. In the embodiment illustrated in Fig. 7, the motion diagram of a single pattern bar shows that the threading rule of the yarn on the same pattern bar may be a series of two continuous threads 52 separated by two void 53 of this cycle, and there is no connecting yarn between the two lengthways of the hollow part to form a mesh opening 8. In this embodiment, the law of the yarn may be a threading pattern of two (e.g., at least two) in and two (e.g., at least) out repeating across the machine. It should be understood that some may fall outside the above described and illustrated ranges and still be consistent with the present disclosure. It should be understood that other patterns can include variations of the same base pattern (e.g., an equal number of in and out stitches alternating to generate the first knit layer 102) . For example and without limitation, the law of the yarn may be a threading pattern of equal parts in and equal parts out repeating across the machine.

As shown in embodiments illustrated in the figures, the yarn Y1 and Y2 on the two pattern bars are symmetrically directed into the needle hook according to the movement rule of Figures 6A, 6B and 8. In at least one embodiment, the coils in the adjacent longitudinal lines may not connected, and they may be inclined in the opposite direction to form a mesh opening 8 as shown in Figures 4 and 8, and the coils in the adjacent longitudinal lines may be connected and close to each other to form strips of fabric 6. The open mesh structure of the first knit layer 12 may include a plurality of openings 8 and strips of fabric 6. In at least one embodiment, the openings 8 in length can have four courses, as shown in the example of Figure 8, but it should be understood that the openings 8 can have any suitable size which can be increased or decreased corresponding number of coils according to the need, especially depending on the desired level of air permeability. In at least one embodiment, the strips of fabric 6 may have four wales, as shown in the examples Figures 4 and 8, in width and six courses, as shown in the example of Figure 6, in length between the mesh holes, but can have any suitable size. While most if not all of the openings fall within the above ranges, it should be understood that some may fall outside the above ranges and still be consistent with the present disclosure.

An embodiment of the structure of the second knit layer 14 is as shown in Figures 9-11. As shown in the example in Figure 12, two pattern bars are directing the full threaded bar to the knitting needle, so that each needle is covered with yarn, so that each needle knits yarn.

In the embodiment of the structure of the second knit layer 14 as shown in the Figures 9-11, and in the example as shown in the Figure 12, the pattern bar L5 drives the yarn Y5 to direct the yarn into the hook 33, and the pattern bar L6 drives the yarn Y6 to direct the yarn into the hook 33, according to the motion law in Figure 10, the stitch formation of one of the pattern bars L5 is recorded as: 1-0/0-1//, where “1-0” corresponds to 59 in the C1 course, “0- 1” corresponds to 60 in the C2 course , and the stitch formation of one of the pattern bars L6 is recorded as: 1-0/2-3/1-0/1-2//, where “1-0” corresponds to 55 in the C1 course, “2-3” corresponds to 56 in the C2 course, “1-0” corresponds to 57 in the C3 course, “1-2” corresponds to 58 in the C4 course . An embodiment of the knitted fabric is shown in Figure 9. Movement pattern of padding yarn of the pattern bars L6 is not limited to the above description, it can be (1-0) . N / (2-3) . N , the value of N is any numerical value such as 1, 2, 3, and greater.

In the structure of the second knit layer 14 as shown in the embodiments of Figures 9-11, the fabric structure of this layer can be a warp plain, generally solid (i.e., no mesh generation) , fabric that traverses across two or more needles, and the two pattern bars are directing yarns to the needles according to the embodiment illustrated in Figures 10 and 11. The length of the extension line 38 can be related to the transverse density of the fabric, and also to the number of needles that are traversed when the yarn is fed, with the more needles through or the smaller the transverse density of the fabric, the longer the corresponding extension line 38.

It should be noted that prior art methods usually use two pattern bars to makes the structure very rigid and with low elasticity. The disadvantage of this product is that it has creases when bent. In at least one embodiment of making the structure of the second knit layer 14 of the present disclosure, the double pattern bars can be used to make the structure rigid and elastic. The length of extension line 38 as shown in Figures 9 and 10 helps to determine the elasticity of the fabric. This structural design meets the customer's requirements for rigidity without wrinkles during bending.

In the middle connecting monofilament 16 as shown in Figures 1-3 and 12, in at least the embodiment illustrated in Figure 12, the two pattern bars L3 and L4 drive the yarns Y3 and Y4 to direct the yarns into the needles hook 31 and 33.

In the middle connecting monofilament 16 structure as shown in Figures 1-3, with the first knit layer 12 and second knit layer 14 in at least the illustrated embodiments, two pattern bars are symmetrical padding yarn, and participate in the knitting of the first knit layer 12 and the second knit layer 14 respectively. Thus, the monofilament 16 can combine with two knit layers 12 and 14 tightly to form the 3D network structure 10. The first knit layer 12 and second knit layers 14 can hold and connect the monofilament 16 firmly through the structure of 6 and 14 in Figures 4 and 9, so that the connecting monofilament 16 is firmly held and fixed. In at least one embodiment, the thickness of the 3D spacer mesh fabric can be determined by the length of the connecting monofilament 16. In at least one embodiment, the fabric thickness can be 6-12 mm, but it should be understood that this is just one example, and the thickness can be adjusted according to the needs with the present disclosure.

In at least certain other embodiments, in order to achieve a spacer fabric 10 that is soft, comfortable, elastic and has good air permeability, a layer, and in certain embodiments, the first knit layer 12, can be provided with a fabric layer interval arranged with mesh openings 8 and plain patterns 6, enabling the mesh to allow the fabric have excellent air permeability. In certain embodiments, the mesh size can be adjusted according to desired ventilation requirement. The plain weave portions can help to make the middle connecting monofilament 16 and the first knit layer 12 more stable and firm. Thus, the stability and straightness of the intermediate connecting monofilament 16 can be relatively good, and inhibit the monofilament from becoming tilted and/or bunched. Due to the action of mesh, the monofilament 16 can be relatively evenly distributed, and the force can be distributed over a relatively larger surface area and help to avoid local collapse. In at least certain other embodiments, the monofilament has good stability due to plain grain consolidation, and it is not easy to fall down laterally, and the elastic recovery of the fabric can be improved relative to other fabrics.

In at least one embodiment, the spacer fabric 10 may include a thickness of 6-12 mm, in another embodiment of 3-6 mm, and in yet another embodiment of 12-15 mm.

The elasticity and support of the 3D spacer fabric 10 may be related to the stiffness of monofilament 16 and the structure and vertical and horizontal density of the fabric. The upper and lower fabric structures of the first knit layer 12 and the second knit layer 14 described above can hold the connecting monofilament 16 well, thereby helping to inhibit the filament 16 from side lodging under external pressure, which helps to inhibit the elasticity and support of the fabric from become poor. In addition, if the stiffness of the intermediate connecting monofilament 16 is too large or too small, the elasticity and comfort of the fabric will be poor. With the increase of the vertical and horizontal density of the fabric, the support will be stronger. In at least one embodiment, the elasticity and support of the fabric can be measured by compression stress value to 6 ± 4 KPa, but it is not limited to this value. In at least one embodiment, the spacer fabric 10 of the present disclosure can include a compression stress value of about 5 ± 2 KPa. Compression stress value can be measured by Test Method: DIN EN ISO 3386-1, Vorkraft 0, 1 Pa; 80x80mm/100mm/min.

The high air permeability of the 3D spacer fabric 10 may be related to the gap between the upper and lower fabrics 12 and 14. Generally speaking, the larger the gap, the better the air permeability, but the size of the fabric gap can restrict the elasticity and support. In at least one embodiment, the air permeability of the spacer fabric 10 can be generally ≥2000 mm/s, but it is not limited to this value. In at least one embodiment, the spacer fabric 10 of the present disclosure can include an air permeability of about ≥5000 mm/s. Air permeability can be measured by Test Method: DIN EN ISO 9237 2 mbar, Test sample: 20 cm².

While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the disclosure. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the disclosure.

The disclosure includes, without limitation, the following embodiments:

1. A spacer fabric comprising a first knit layer; a second knit layer, and spacer yarns extending between and connecting the first and second knit layers; wherein the first knit layer includes a mesh structure comprising a plurality of spaced openings separated by a plurality of plain fabric sections; the second knit layer includes a plain structure; and the first knit layer comprises a series of at least two threads separated by a void of at least two threads

2. The spacer fabric according to any of the preceding embodiments, wherein the spacer yarns comprise about 95%polyethylene terephthalate (PET) .

3. The spacer fabric according to any of the preceding embodiments, wherein the spacer yarns comprise about 95%recycled plastic.

4. The spacer fabric according to any of the preceding embodiments, wherein the first knit layer includes a plurality of spaced openings disposed in an offset configuration.

5. The spacer fabric according to any of the preceding embodiments, wherein the first knit layer, the second knit layer, and the spacer yarns form an integral three-dimensional network structure.

6. The spacer fabric according to any of the preceding embodiments, wherein the second knit layer comprises a multi strand polyester filament having a size of about 110 dtex/1F.

7. The spacer fabric according to any of the preceding embodiments, wherein the first knit layer comprises a multi strand polyester filament having a size of about 83 dtex/1F.

8. The spacer fabric according to any of the preceding embodiments, wherein the spacer yarns include a size of about 44dtex/1F.

9. The spacer fabric according to any of the preceding embodiments, wherein the plurality of spaced openings include a size of 7 courses in length.

10. The spacer fabric according to any of the preceding embodiments, wherein the plurality of spaced openings include a size of a one wale in width.

11. The spacer fabric according to any of the preceding embodiments, wherein the plurality of plain fabric sections include a size of 4 wales in width; and the plurality of fabric sections include the same length as the plurality of spaced openings.

12. The spacer fabric according to any of the preceding embodiments, wherein the second knit layer is formed via a first pattern bar knitting a first portion of yarn and a second pattern bar knitting a second portion of yarn.

13. The spacer fabric according to any of the preceding embodiments, wherein the first portion of yarn runs along a single wale.

14. The spacer fabric according to any of the preceding embodiments, wherein the second portion of yarn alternates between running along one, two, and three wales.

15. The spacer fabric according to any of the preceding embodiments, wherein: the second portion of yarn includes a first section and a second section; yarns of the first section run along three wales; and yarns of the second section run along two wales.

16. The spacer fabric according to any of the preceding embodiments, wherein the second pattern bar alternates between the first section and the second section in knitting the second portion of yarn.

17. The spacer fabric according to any of the preceding embodiments, wherein the first portion of yarn includes a series of alternating pillar stitches.

18. The spacer fabric according to any of the preceding embodiments, wherein the first portion of yarn includes a series of modified pillar stitches over a single course in width.

19. The spacer fabric according to any of the preceding embodiments, wherein the spacer fabric is formed as part of a cushion layer of a vehicle seat trim cover.

20. The spacer fabric according to any of the preceding embodiments, wherein the plurality of spaced openings of the spacer fabric are generally circular, elongated, oval, square, and/or rectangular in shape.

21. A spacer fabric comprising: a first knit layer; a second knit layer; andspacer yarns extending between and connecting the first and second knit layers, the first knit layer having a mesh structure comprising a plurality of spaced openings separated by plain fabric sections, the second knit layer having varying plain structure; wherein the spacer fabric has a compression stress value to 6 ± 4 KPa and an air permeability of ≥2000 l/dm2*min.

22. The spacer fabric according to any of the preceding embodiments, wherein the plurality of spaced openings are spaced apart in offset rows.

23. The spacer fabric according to any of the preceding embodiments, wherein the plurality of spaced openings are generally circular, elongated, oval, square and/or rectangular in shape.

24. The spacer fabric according to any of the preceding embodiments, wherein the plurality of spaced openings are spaced 0.5 to 20 mm, on center, in a width direction and are spaced 0.5 to 20 mm, on center in a length direction.

25. The spacer fabric according to any of the preceding embodiments, wherein the first and second knit layers together with the spacer yarns form an integral three-dimensional network structure, and a mesh surface of the first knit layer has half the number of warp pieces compared to second knit layer.

26. The spacer fabric according to any of the preceding embodiments, wherein the spacer fabric comprises a cushion layer in a vehicle seat trim cover.

27. The spacer fabric according to any of the preceding embodiments, wherein the first knit layer has a higher air permeability than the second knit layer.

28. A spacer fabric comprising: a first knit layer; a second knit layer; and spacer yarns extending between and connecting the first and second knit layers, the first knit layer having a mesh structure comprising a plurality of spaced openings separated by fabric sections, wherein each of the plurality of spaced openings comprises one wale in width and at least two courses in length.

29. The spacer fabric according to any of the preceding embodiments, wherein spacer fabric has a thickness of between 3 and 15 mm.

30. The spacer fabric according to any of the preceding embodiments, wherein the spacer fabric is attached to leather, PVC, polyurethane, fabric or other material by a tack-sew process or by glue lamination with a glue web or other glue solutions.

Various examples/embodiments are described herein for various apparatuses, systems, and/or methods. Numerous specific details are set forth to provide a thorough understanding of the overall structure, function, manufacture, and use of the examples/embodiments as described in the specification and illustrated in the accompanying drawings. It will be understood by those skilled in the art, however, that the examples/embodiments may be practiced without such specific details. In other instances, well-known operations, components, and elements have not been described in detail so as not to obscure the examples/embodiments described in the specification. Those of ordinary skill in the art will understand that the examples/embodiments described and illustrated herein are non-limiting examples, and thus it can be appreciated that the specific structural and functional details disclosed herein may be representative and do not necessarily limit the scope of the embodiments.

Reference throughout the specification to “examples, “in examples, ” “with examples, ” “various embodiments, ” “with embodiments, ” “in embodiments, ” or “an embodiment, ” or the like, means that a particular feature, structure, or characteristic described in connection with the example/embodiment is included in at least one embodiment. Thus, appearances of the phrases “examples, “in examples, ” “with examples, ” “in various embodiments, ” “with embodiments, ” “in embodiments, ” or “an embodiment, ” or the like, in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more examples/embodiments. Thus, the particular features, structures, or characteristics illustrated or described in connection with one embodiment/example may be combined, in whole or in part, with the features, structures, functions, and/or characteristics of one or more other embodiments/examples without limitation given that such combination is not illogical or non-functional. Moreover, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the scope thereof.

It should be understood that references to a single element are not necessarily so limited and may include one or more of such element. Any directional references (e.g., plus, minus, upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are only used for identification purposes to aid the reader’s understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of examples/embodiments.

“One or more” includes a function being performed by one element, a function being performed by more than one element, e.g., in a distributed fashion, several functions being performed by one element, several functions being performed by several elements, or any combination of the above.

It will also be understood that, although the terms first, second, etc. are, in some instances, used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of the various described embodiments. The first element and the second element are both element, but they are not the same element.

The terminology used in the description of the various described embodiments herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms “a” , “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “includes, ” “including, ” “comprises, ” and/or “comprising, ” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

Joinder references (e.g., attached, coupled, connected, and the like) are to be construed broadly and may include intermediate members between a connection of elements, relative movement between elements, direct connections, indirect connections, fixed connections, movable connections, operative connections, indirect contact, and/or direct contact. As such, joinder references do not necessarily imply that two elements are directly connected/coupled and in fixed relation to each other. Connections of electrical components, if any, may include mechanical connections, electrical connections, wired connections, and/or wireless connections, among others. Uses of “e.g. ” and “such as” in the specification are to be construed broadly and are used to provide non-limiting examples of embodiments of the disclosure, and the disclosure is not limited to such examples.

While processes, systems, and methods may be described herein in connection with one or more steps in a particular sequence, it should be understood that such methods may be practiced with the steps in a different order, with certain steps performed simultaneously, with additional steps, and/or with certain described steps omitted.

As used herein, the term “if” is, optionally, construed to mean “when” or “upon” or “in response to determining” or “in response to detecting, ” depending on the context. Similarly, the phrase “if it is determined” or “if [a stated condition or event] is detected” is, optionally, construed to mean “upon determining” or “in response to determining” or “upon detecting [the stated condition or event] ” or “in response to detecting [the stated condition or event] , ” depending on the context.

All matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure may be made without departing from the present disclosure.

Claims

A spacer fabric comprising:

a first knit layer;

a second knit layer; and

spacer yarns extending between and connecting the first and second knit layers,

wherein the first knit layer includes a mesh structure comprising a plurality of spaced openings separated by a plurality of plain fabric sections;

the second knit layer includes a plain structure; and

the first knit layer comprises a series of at least two threads separated by a void of at least two threads.
The spacer fabric of claim 1, wherein the spacer yarns comprise about 95%polyethylene terephthalate (PET) .
The spacer fabric of claim 1, wherein the spacer yarns comprise about 95%recycled plastic.
The spacer fabric of claim 1, wherein the plurality of spaced openings are disposed in an offset configuration.
The spacer fabric of claim 1, wherein the first knit layer, the second knit layer, and the spacer yarns form an integral three-dimensional network structure.
The spacer fabric of claim 1, wherein the second knit layer comprises a multi strand polyester filament having a size of about 110 dtex/1F.
The spacer fabric of claim 6, wherein the first knit layer comprises a multi strand polyester filament having a size of about 83 dtex/1F.
The spacer fabric of claim 7, wherein the spacer yarns include a size of about 44dtex/1F.
The spacer fabric of claim 1, wherein the plurality of spaced openings include a size of 7 courses in length.
The spacer fabric of claim 9, wherein the plurality of spaced openings include a size of a one wale in width.
The spacer fabric of claim 10, wherein the plurality of plain fabric sections include a size of 4 wales in width; and the plurality of plain fabric sections include the same length as the plurality of spaced openings.
The spacer fabric of claim 1, wherein the second knit layer is formed via a first pattern bar knitting a first portion of yarn and a second pattern bar knitting a second portion of yarn.
The spacer fabric of claim 12, wherein the first portion of yarn runs along a single wale.
The spacer fabric of claim 13, wherein the second portion of yarn alternates between running along one, two, and three wales.
The spacer fabric of claim 14, wherein the second portion of yarn includes a first section and a second section; yarns of the first section run along three wales; and yarns of the second section run along two wales.
The spacer fabric of claim 15, wherein the second pattern bar alternates between the first section and the second section in knitting the second portion of yarn.
The spacer fabric of claim 12, wherein the first portion of yarn includes a series of alternating pillar stitches.
The spacer fabric of claim 12, wherein the first portion of yarn includes a series of modified pillar stitches over a single course in width.
The spacer fabric of claim 1, wherein the spacer fabric is formed as part of a cushion layer of a vehicle seat trim cover.
The spacer fabric of claim 4, wherein the spaced openings of the spacer fabric are generally circular, elongated, oval, square, and/or rectangular in shape.
A spacer fabric comprising:

a first knit layer;

a second knit layer; and

spacer yarns extending between and connecting the first and second knit layers,

the first knit layer having a mesh structure comprising a plurality of spaced openings separated by plain fabric sections,

the second knit layer having varying plain structure;

wherein the spacer fabric has a compression stress value of 6 ± 4 KPa and an air permeability of at least 2000 l/dm2*min.
The spacer fabric of claim 21, wherein the plurality of spaced openings are spaced apart in offset rows.
The spacer fabric of claim 22, wherein the plurality of spaced openings are generally circular, elongated, oval, square and/or rectangular in shape.
The spacer fabric of claim 23, wherein the plurality of spaced openings are spaced 0.5 to 20 mm, on center, in a width direction and are spaced 0.5 to 20 mm, on center in a length direction.
The spacer fabric of claim 21 wherein the first and second knit layers together with the spacer yarns form an integral three-dimensional network structure, and a mesh surface of the first knit layer has half the number of warp pieces compared to the second knit layer.
The spacer fabric of claim 21, wherein the spacer fabric comprises a cushion layer in a vehicle seat trim cover.
The spacer fabric of claim 21, wherein the first knit layer has a higher air permeability than the second knit layer.
A spacer fabric comprising:

a first knit layer;

a second knit layer; and

spacer yarns extending between and connecting the first and second knit layers,

the first knit layer having a mesh structure comprising a plurality of spaced openings separated by fabric sections,

wherein each of the plurality of spaced openings comprises one wale in width and at least two courses in length.
The spacer fabric of claim 28, wherein the spacer fabric has a thickness of between 3 and 15 mm.
The spacer fabric of claim 28, wherein the spacer fabric is attached to leather, PVC, polyurethane, fabric or other material by a tack-sew process or by glue lamination with a glue web or other glue solutions.