INSULATING DOUBLE-KNIT FABRIC
The invention related to an insulating, double-knit fabric comprising an outer knit layer and an inner knit layer coupled with the outer knit layer forming a plurality of elongated air pockets in a plurality of rows. Only the outer layer comprises a plurality of windows, where the air pockets comprise intermediate fiber regions and the intermediate fiber regions comprise fibers positioned parallel to the inner and outer knit layers.
1 . An insulating, double-knit fabric comprising an outer knit layer and an inner knit layer coupled with the outer knit layer forming a plurality of elongated air pockets in a plurality of rows, wherein only the outer layer comprises a plurality of windows, wherein the air pockets comprise intermediate fiber regions, and wherein the intermediate fiber regions comprise fibers positioned parallel to the inner and outer knit layers.
2 . The insulating, double-knit fabric of claim 1 , wherein the windows are spaced apart in the outer knit layer.
3 . The insulating, double-knit fabric of claim 1 , wherein the fibers in the intermediate fiber regions have a length greater than at least five times the width of the windows in the outer knit layer.
4 . The insulating, double-knit fabric of claim 1 , wherein the first knit layer comprises first yarns and the second knit layer comprises second yarns, wherein the first knit layer and the second knit layer comprise a denier gradient such that the first yarns have a finer denier than the second yarns or the second yarns have a finer denier than the first yarns.
5 . The insulating, double-knit fabric of claim 1 , wherein the first knit layer comprises first yarns and the second knit layer comprises second yarns, and wherein the first yarns and the second yarns have a finer denier than the rows of fibers of the plurality of intermediate fiber regions.
6 . The insulating, double-knit fabric of claim 1 , wherein the plurality of fibers of the intermediate fiber regions comprise a low melt fiber.
7 . The insulating, double-knit fabric of claim 1 , wherein the plurality of fibers of the intermediate fiber regions comprise at least one of a bi-component filament, a polyester blend, and a polyamide.
8 . The insulating, double-knit fabric of claim 1 , wherein the bi-component filament comprises modacrylic fiber and cellulosic fiber.
9 . The insulating, double-knit fabric of claim 1 , wherein the first knit layer and the second knit layer comprise a material selected from the group consisting of polyester, polypropylene, nylon, wool, cellulosic fibers, flame resistant fibers, modacrylic fibers, and polyamide fibers.
10 . The insulating, double-knit fabric of claim 1 , wherein the first knit layer and the second knit layer comprise a circular knit.
11 . A garment comprising the insulating, double-knit fabric of claim 1 .
12 . A fabric article comprising the insulating, double-knit fabric of claim 1 .