Knit elastic mesh loop pile fabric for orthopedic and other devices

Abstract

An improved fabric for orthopedic devices is provided, being a knitted fabric produced on either a warp or weft knit system and utilizing a filament yarn selected from nylon and polyester as well as spandex. The fabric enhances freedom of movement while stimulating blood flow and muscle tone. The fabric has an elasticity that enables closure of orthopedic and other devices by placing the hook component of a Velcro (®) strip at any convenient point rather than aligning it with the loop component of the Velcro (®). The fabric is more convenient, faster and easier for many incapacitated persons, enhancing wearing comfort. Its mesh structure makes it more porous, which enhances the air circulation and the moisture management in creating a cooling effect on the wearer's skin and ready evaporation of perspiration, while still providing therapeutic warmth without heat buildup.

1 . A knit fabric comprising:
 filament yarns selected from yarns of the group consisting of nylon yarns and polyester yarns and present in an amount between about 85 and 95% weight percent;   spandex yarns integrally knit with the filament yarns in an amount between about 5 and 15 weight percent;   wherein the fabric has a mesh construction;   wherein the fabric has a loop pile construction along one side thereof.   
   
   
       2 . The fabric of  claim 1 , wherein the filament yarns comprise nylon yarns. 
   
   
       3 . The fabric of  claim 1 , wherein the spandex yarns have an elongation at break of between about 300% and 700%. 
   
   
       4 . The fabric of  claim 1 , wherein the mesh construction of the fabric defines a plurality of openings, each having a pore size of between about 1 and 3 mm. in diameter. 
   
   
       5 . The fabric of  claim 1 , wherein said fabric is produced by a warp knitting process. 
   
   
       6 . The fabric of  claim 1 , wherein said loop pile construction is produced by a process selected from the group consisting of napping, overfeeding of the yarns, pressing off, and yarn manipulation. 
   
   
       7 . The fabric of  claim 1 , wherein said loop pile construction is produced by a napping process. 
   
   
       8 . The fabric of  claim 1 , wherein the filament yarns have a tenacity of between about 4 and 7 grams/denier. 
   
   
       9 . The fabric of  claim 1 , wherein the filament yarns have a filament denier of between about 40 and 70. 
   
   
       10 . The fabric of  claim 9 , wherein the number of filaments per yarn of the filament yarns is between about 10 and 24. 
   
   
       11 . The fabric of  claim 9 , wherein the spandex yarns have a denier of between about 40 and 70. 
   
   
       12 . The fabric of  claim 3 , wherein the fabric has a widthwise stretch of between about 75% and 125% and a lengthwise stretch of between about 25% and 60%. 
   
   
       13 . The fabric of  claim 1 , wherein the mesh construction of the fabric defines a plurality of openings having a widthwise mesh count of between about 5 and 18 meshes/inch and lengthwise mesh count of between about 4 and 6 meshes/inch. 
   
   
       14 . The fabric of  claim 10 , wherein the spandex yarns have a denier of between about 40 and 70. 
   
   
       15 . The fabric of  claim 13 , wherein said plurality of openings each has a size between about 1 and 3 mm. in diameter. 
   
   
       16 . The fabric of  claim 1 , wherein:
 the filament yarns comprise nylon yarns;   the fabric is produced by warp knitting;   the loop pile construction is produced by a napping process.   
   
   
       17 . The fabric of  claim 16 , wherein the mesh construction of the fabric defines a plurality of openings having a widthwise mesh count of between about 5 and 18 meshes/inch and lengthwise mesh count of between about 4 and 6 meshes/inch. 
   
   
       18 . The fabric of  claim 16 , wherein the nylon yarns have a tenacity of between about 4 and 7 grams/denier. 
   
   
       19 . The fabric of  claim 17 , wherein the filament yarns have a filament denier of between about 40 and 70 and the spandex yarns have a denier of between about 40 and 70. 
   
   
       20 . The fabric of  claim 19 , wherein the spandex yarns have an elongation at break of between about 300% and 700%. 
   
   
       21 . A knit fabric comprising:
 filament yarns and spandex yarns integrally knit with the filament yarns;   wherein the fabric has a mesh construction as well as a loop piles along one side thereof.   
   
   
       22 . A method for producing a fabric comprising:
 integrally knitting filament yarns selected from the group consisting of nylon yarns and polyester yarns with spandex yarns in order to produce a fabric with a mesh construction; and   generating a loop pile along one surface of said fabric.   
   
   
       23 . The method of  claim 22 , wherein said loop pile is generated by a napping process.