Warp knitted textile spacer fabric, method of producing same, and products produced therefrom

Claim 2

A warp knitted textile spacer fabric of the double needle bar Raschel pile type having characteristics of stretchability, compressibility and resiliency simulative of resilient plastic foam materials and having characteristics of air and moisture permeability substantially enhanced over said foam materials, said spacer fabric comprising front and back stretchable fabric substructures and a pile substructure integrated with and extending between the front and back fabric substructures for maintaining the front and back fabric substructures in spaced parallel relation and being resiliently yieldable for compressibility of the front and back fabric substructures together and subsequent recovery thereof to spaced parallel relation, said spacer fabric being of an at least six-bar warp knitted Raschel construction wherein each said fabric substructure comprises at least a set of ground yarns and a set of stretchable yarns interknitted with one another in a stretchable resilient stitch construction having needle loops of said ground and stretchable yarns arranged in longitudinal wales and transverse courses and said pile substructure comprises at least two sets of monofilament pile yarns interknitted with each said fabric substructure in a stitch construction forming pile segments which extend transversely between said fabric substructures in differing angular orientations relative thereto for permitting resilient compressibility of said fabric substructures while resisting relative shear movement of said fabric substructures in directions parallel thereto, each pile yarn of at least one of said two sets of pile yarns being formed in successive needle loops which alternate every course between non-corresponding wales of said front and back fabric substructures including alternating needle loops formed alternatingly in spaced wales of successive courses of one of said front and back fabric substructures and intervening needle loops formed in a common wale of successive courses of the other of said front and back fabric substructures.

Claim 3

A warp knitted textile spacer fabric according to claim 1, wherein said monofilament pile yarns are of relatively fine deniers in the range of about 40 denier and less.

Claim 4

A warp knitted textile spacer fabric according to claim 2, wherein said monofilament pile yarns are of relatively fine deniers in the range of about 30 denier and less.

Claim 5

A warp knitted textile spacer fabric according to claim 2, wherein said monofilament pile yarns are polyester.

Claim 6

A warp knitted textile spacer fabric according to claim 1, wherein said stretchable yarns are elastic yarns.

Claim 7

A warp knitted textile spacer fabric according to claim 1, wherein said ground yarns are dyeable by a heat transfer dye process.

Claim 8

A warp knitted textile spacer fabric according to claim 1, wherein each pile yarn of said two sets of pile yarns is formed in successive needle loops which alternate every course between non-corresponding wales of said front and back fabric substructures.

Claim 9

A warp knitted textile spacer fabric according to claim 7, wherein the successive needle loops of each pile yarn of said two sets of pile yarns comprise alternating needle loops formed alternatingly in spaced wales of successive courses of one of said front and back fabric substructures and intervening needle loops formed in a common wale of successive courses of the other of said front and back fabric substructures.

Claim 10

A warp knitted textile spacer fabric according to claim 8, wherein said spaced wales of said alternating pile yarn needle loops are separated by at least one intervening wale of said one fabric substructure.

Claim 11

A warp knitted textile spacer fabric according to claim 9, wherein one said set of monofilament pile yarns are warp knitted between said front and back fabric substructures in a 1-0, 2-3, 4-5, 3-2 stitch construction and the other said set of monofilament pile yarns are warp knitted between said front and back fabric substructures in a 5-4, 2-3, 0-1, 3-2 stitch construction.

Claim 12

A warp knitted textile spacer fabric according to claim 9, wherein one said set of monofilament pile yarns are warp knitted between said front and back fabric substructures in a 1-0, 1-2, 2-3, 2-1 stitch construction and the other said set of monofilament pile yarns are warp knitted between said front and back fabric substructures in a 2-3, 2-1, 1-0, 1-2 stitch construction.

Claim 13

A warp knitted textile spacer fabric according to claim 9, wherein one said set of monofilament pile yarns are warp knitted between said front and back fabric substructures in a 1-0, 2-3, 4-5, 3-2 stitch construction and the other said set of monofilament pile yarns are warp knitted between said front and back fabric substructures in a 4-5, 3-2, 1-0, 2-3 stitch construction.

Claim 14

A warp knitted textile spacer fabric according to claim 9, wherein one said set of monofilament pile yarns are warp knitted between said front and back fabric substructures in a 1-0, 3-4, 6-7, 4-3 stitch construction and the other said set of monofilament pile yarns are warp knitted between said front and back fabric substructures in a 6-7, 4-3, 1-0, 3-4 stitch construction.

Claim 15

A warp knitted textile spacer fabric according to claim 9, wherein one said set of monofilament pile yarns are warp knitted between said front and back fabric substructures in a 1-0, 4-5, 8-9, 5-4 stitch construction and the other said set of monofilament pile yarns are warp knitted between said front and back fabric substructures in an 8-9, 5-4, 1-0, 4-5 stitch construction.

Claim 16

A warp knitted textile spacer fabric according to claim 8, wherein said spaced wales of said alternating pile yarn needle loops are separated by at least three intervening wales of said one fabric substructure.

Claim 17

A warp knitted textile spacer fabric according to claim 8, wherein said spaced wales of said alternating pile yarn needle loops are separated by at least five intervening wales of said one fabric substructure.

Claim 18

A warp knitted textile spacer fabric according to claim 8, wherein said spaced wales of said alternating pile yarn needle loops are separated by at least seven intervening wales of said one fabric substructure.

Claim 19

A warp knitted textile spacer fabric according to claim 1, wherein each said ground yarn of one of said front and back fabric substructures is warp knitted in an 0-1, 1-1, 3-2, 2-2 stitch construction, each said stretchable yarn of said one fabric substructure is warp knitted in a 2-1, 1-1, 0-1, 1-1 stitch construction, each said ground yarn of the other fabric substructure is warp knitted in a 1-1, 3-2, 2-2, 0-1 stitch construction, and each said stretchable yarn of said other fabric substructure is warp knitted in a 1-1, 0-1, 1-1, 2-1 stitch construction.

Claim 20

A warp knitted textile spacer fabric according to claim 1, wherein said pile segments of said two sets of pile yarns cooperate to act as a pyramidal system of triangularly related trusses for supporting and maintaining said front and back fabric substructures in compressible spaced parallel relation and for resisting relative shear movement thereof in response to forces exerted in directions generally parallel to said fabric substructures.

Claim 21

An athletic shoe comprising a cushioning component formed of said textile fabric of claim 1.

Claim 22

An athletic shoe according to claim 20, wherein said cushioning component is a sleeve-like bootie integrally formed interiorly within the shoe for receiving a wearer's foot.

Claim 23

An athletic shoe according to claim 20, wherein said cushioning component is an insole.

Claim 24

An athletic shoe according to claim 20, wherein said cushioning component is a tongue.

Claim 25

A limb support device comprising said textile fabric of claim 1.

Claim 26

A limb support device according to claim 24 and further comprising a wrap for a human joint wherein said wrap is formed of said textile fabric.

Claim 27

A warp knitted textile spacer fabric of the double needle bar Raschel pile type having characteristics of stretchability, compressibility and resiliency simulative of resilient plastic foam materials and having characteristics of air and moisture permeability substantially enhanced over said foam materials, said spacer fabric comprising front and back stretchable fabric substructures and a pile substructure integrated with and extending between the front and back fabric substructures for maintaining the front and back fabric substructures in spaced parallel relation and being resiliently yieldable for compressibility of the front and back fabric substructures together and subsequent recovery thereof to spaced parallel relation, said spacer fabric being of an at least seven-bar ward knitted Raschel construction wherein each said fabric substructure comprises at least a set of ground yarns and a set of stretchable yarns interknitted with one another in a stretchable resilient stitch construction and said pile substructure comprises at least two sets of monofilament pile yarns interknitted with each said fabric substructure in a stitch construction forming pile segments which extend transversely between said fabric substructures in differing angular orientations relative thereto for permitting resilient compressibility of said fabric substructures while resisting relative shear movement of said fabric substructures in directions parallel thereto and a third set of monofilament pile yarns interknitted with each said fabric substructure in a chain stitch construction forming pile segments which extend transversely between said fabric substructures.

Claim 28

A warp knitted textile spacer fabric of the double needle bar Raschel pile type having characteristics of stretchability, compressibility and resiliency simulative of resilient plastic foam materials and having characteristics of air and moisture permeability substantially enhanced over said foam materials, said spacer fabric comprising front and back stretchable fabric substructures and a pile substructure integrated with and extending between the front and back fabric substructures for maintaining the front and back fabric substructures in spaced parallel relation and being resiliently yieldable for compressibility of the front and back fabric substructures together and subsequent recovery thereof to spaced parallel relation, said spacer fabric being of an at least seven-bar ward knitted Raschel construction wherein each said fabric substructure comprises at least a set of ground yarns and a set of stretchable yarns interknitted with one another in a stretchable resilient stitch construction and said pile substructure comprises at least two sets of monofilament pile yarns interknitted with each said fabric substructure in a stitch construction forming pile segments which extend transversely between said fabric substructures in differing angular orientations relative thereto for permitting resilient compressibility of said fabric substructures while resisting relative shear movement of said fabric substructures in directions parallel thereto and a third set of monofilament pile yarns interknitted with each said fabric substructure in a chain stitch construction forming pile segments which extend transversely between said fabric substructures.

Claim 29

A warp knitted textile spacer fabric according to claim 26, wherein each pile yarn of said third set of pile yarns is formed in successive needle loops which alternate every course between corresponding wales of said front and back fabric substructures.

Claim 30

A warp knitted textile spacer fabric according to claim 27, wherein said third set of monofilament pile yarns are warp knitted between said front and back fabric substructures in a 1-0, 0-1, 0-1, 1-0 chain stitch construction.

Claim 31

A warp knitted textile spacer fabric according to claim 27, wherein said third set of monofilament pile yarns are warp knitted between said front and back fabric substructures in a 1-0, 0-0, 0-0, 0-1, 1-1, 1-1 chain stitch construction.

Claim 32

A warp knitted textile spacer fabric according to claim 27, wherein said pile segments of said three sets of pile yarns cooperate to act as a pyramidal system of triangularly related trusses for supporting and maintaining said front and back fabric substructures in compressible spaced parallel relation and for resisting relative shear movement thereof in response to forces exerted in directions generally parallel to said fabric substructures.

Claim 33

An athletic shoe comprising a cushioning component formed of said textile fabric of claim 30.

Claim 34

A limb support device comprising said textile fabric of claim 30.

Claim 35

A warp knitted textile spacer fabric according to claim 30, wherein each said triangularly related truss comprises six pile segments including a pair of pile segments of each of said three sets of pile yarns, said six pile segments extending from six respective spaced-apart needle loops formed in one of said front and back fabric substructures and converging together in six respective plated needle loops of said pile yarns formed in a common course and wale of the other of said front and back fabric substructures.

Claim 36

A warp knitted textile spacer fabric according to claim 33, wherein each said ground yarn of one of said front and back fabric substructures is warp knitted in an 0-1, 1-1, 3-2, 2-2 stitch construction, each said stretchable yarn of said one fabric substructure is warp knitted in a 2-1, 1-1, 0-1, 1-1 stitch construction, each said ground yarn of the other fabric substructure is warp knitted in a 1-1, 3-2, 2-2, 0-1 stitch construction, and each said stretchable yarn of said other fabric substructure is warp knitted in a 1-1, 0-1, 1-1, 2-1 stitch construction.

Claim 37

An athletic shoe comprising a cushioning component formed of said textile fabric of claim 33.

Claim 38

A limb support device comprising said textile fabric of claim 33.

Claim 39

A warp knitted textile spacer fabric according to claim 26, wherein each said ground yarn of one of said front and back fabric substructures is warp knitted in an 0-1, 1-1, 3-2, 2-2 stitch construction, each said stretchable yarn of said one fabric substructure is warp knitted in a 2-1, 1-1, 0-1, 1-1 stitch construction, each said ground yarn of the other fabric substructure is warp knitted in a 1-1, 3-2, 2-2, 0-1 stitch construction, and each said stretchable yarn of said other fabric substructure is warp knitted in a 1-1, 0-1, 1-1, 2-1 stitch construction.

Claim 40

An athletic shoe comprising a cushioning component formed of said textile fabric of claim 26.

Claim 41

A limb support device comprising said textile fabric of claim 26.

Claim 42

A warp knitted textile spacer fabric of the double needle bar Raschel pile type having characteristics of stretchability, compressibility and resiliency simulative of resilient plastic foam materials and having characteristics of air and moisture permeability substantially enhanced over said foam materials, said spacer fabric comprising front and back stretchable fabric substructures and a pile substructure integrated with and extending between the front and back fabric substructures for maintaining the front and back fabric substructures in spaced parallel relation and being resiliently yieldable for compressibility of the front and back fabric substructures together and subsequent recovery thereof to spaced parallel relation, said spacer fabric being of an at least six-bar warp knitted Raschel construction wherein each said fabric substructure comprises at least a set of ground yarns and a set of stretchable yarns interknitted with one another in a stretchable resilient stitch construction having needle loops of said ground and stretchable yarns arranged in longitudinal wales and transverse courses and said pile substructure comprises at least two sets of monofilament pile yarns interknitted with each said fabric substructure in a stitch construction forming pile segments which extend transversely between said fabric substructures in differing angular orientations relative thereto for permitting resilient compressibility of said fabric substructures while resisting relative shear movement of said fabric substructures in directions parallel thereto, said pile segments of said two sets of pile yarns cooperating to act as a pyramidal system of triangularly related trusses for supporting and maintaining said front and back fabric substructures in compressible spaced parallel relation and for resisting relative shear movement thereof in response to forces exerted in directions generally parallel to said fabric substructures, each said triangularly related truss comprising four pile segments including a pair of pile segments of each of said two sets of pile yarns, said four pile segments extending from four respective spaced-apart needle loops formed in one of said front and back fabric substructures and converging together in four respective plated needle loops of said pile yarns formed in a common course and wale of the other of said front and back fabric substructures.

Claim 43

A warp knitted textile spacer fabric of the double needle bar Raschel pile type having characteristics of stretchability, compressibility and resiliency simulative of resilient plastic foam materials and having characteristics of air and moisture permeability substantially enhanced over said foam materials, said spacer fabric comprising front and back stretchable fabric substructures and a pile substructure integrated with and extending between the front and back fabric substructures for maintaining the front and back fabric substructures in spaced parallel relation and being resiliently yieldable for compressibility of the front and back fabric substructures together and subsequent recovery thereof to spaced parallel relation, said spacer fabric being of an at least six-bar warp knitted Raschel construction wherein each said fabric substructure comprises at least a set of ground yarns and a set of stretchable yarns interknitted with one another in a stretchable resilient stitch construction having needle loops of said ground and stretchable yarns arranged in longitudinal wales and transverse courses and said pile substructure comprises at least two sets of monofilament pile yarns interknitted with each said fabric substructure in a stitch construction forming pile segments which extend transversely between said fabric substructures in differing angular orientations relative thereto for permitting resilient compressibility of said fabric substructures while resisting relative shear movement of said fabric substructures in directions parallel thereto, said pile segments of said two sets of pile yarns cooperating to act as a pyramidal system of triangularly related trusses for supporting and maintaining said front and back fabric substructures in compressible spaced parallel relation and for resisting relative shear movement thereof in response to forces exerted in directions generally parallel to said fabric substructures, each said triangularly related truss comprising four pile segments including a pair of pile segments of each of said two sets of pile yarns, said four pile segments extending from four respective spaced-apart needle loops formed in one of said front and back fabric substructures and converging together in four respective plated needle loops of said pile yarns formed in a common course and wale of the other of said front and back fabric substructures.

Claim 44

An athletic shoe comprising a cushioning component formed of said textile fabric of claim 40.

Claim 45

A limb support device comprising said textile fabric of claim 40.

Claim 46

A process for producing a warp knitted spacer fabric of the double needle bar Raschel pile type having characteristics of stretchability, compressibility and resiliency simulative of resilient plastic foam materials and having characteristics of air and moisture permeability substantially enhanced over said foam materials, said process comprising the steps of warp knitting on a double needle bar Raschel knitting machine having at least six yarn guide bars an at least six bar spacer fabric comprising front and back stretchable fabric substructures and a pile substructure integrated with and extending between the front and back fabric substructures for maintaining the front and back fabric substructures in spaced parallel relation and being resiliently yieldable for compressibility of the front and back fabric substructures together and subsequent recovery thereof to spaced parallel relation, said knitting steps comprising forming each said fabric substructure by interknitting at least a set of ground yarns and a set of stretchable yarns with one another in a stretchable resilient stitch construction having needle loops of said ground and stretchable yarns arranged in longitudinal wales and transverse courses and forming said pile substructure by interknitting at least two sets of monofilament pile yarns with each said fabric substructure in a stitch construction forming pile segments which extend transversely between said fabric substructures in differing angular orientations relative thereto for permitting resilient compressibility of said fabric substructures while resisting relative shear movement of said fabric substructures in directions parallel thereto and forming each pile yarn of at least one of said two sets of pile yarns in successive needle loops which alternate every course between non-corresponding wales of said front and back fabric substructures including alternating needle loops arranged alternatingly in spaced wales of successive courses of one of said front and back fabric substructures and intervening needle loops arranged in a common wale of successive courses of the other of said front and back fabric substructures.

Claim 47

A process for producing a warp knitted spacer fabric of the double needle bar Raschel pile type having characteristics of stretchability, compressibility and resiliency simulative of resilient plastic foam materials and having characteristics of air and moisture permeability substantially enhanced over said foam materials, said process comprising the steps of warp knitting on a double needle bar Raschel knitting machine having at least six yarn guide bars an at least six bar spacer fabric comprising front and back stretchable fabric substructures and a pile substructure integrated with and extending between the front and back fabric substructures for maintaining the front and back fabric substructures in spaced parallel relation and being resiliently yieldable for compressibility of the front and back fabric substructures together and subsequent recovery thereof to spaced parallel relation, said knitting steps comprising forming each said fabric substructure by interknitting at least a set of ground yarns and a set of stretchable yarns with one another in a stretchable resilient stitch construction having needle loops of said ground and stretchable yarns arranged in longitudinal wales and transverse courses and forming said pile substructure by interknitting at least two sets of monofilament pile yarns with each said fabric substructure in a stitch construction forming pile segments which extend transversely between said fabric substructures in differing angular orientations relative thereto for permitting resilient compressibility of said fabric substructures while resisting relative shear movement of said fabric substructures in directions parallel thereto and forming each pile yarn of at least one of said two sets of pile yarns in successive needle loops which alternate every course between non-corresponding wales of said front and back fabric substructures including alternating needle loops arranged alternatingly in spaced wales of successive courses of one of said front and back fabric substructures and intervening needle loops arranged in a common wale of successive courses of the other of said front and back fabric substructures.

Claim 48

A process for producing a warp knitted spacer fabric according to claim 43 and further comprising the steps of, after knitting, stretching said spacer fabric into a predetermined stretched condition wherein said spacer fabric retains a desired degree of residual stretchability, compressibility and resiliency while said monofilament pile yarns are substantially withdrawn interiorly into said spacer fabric from said fabric substructures and, while maintaining said spacer fabric in said stretched condition, heat setting said spacer fabric to fix said spacer fabric dimensionally and structurally in said stretched condition.

Claim 49

A process for producing a warp knitted spacer fabric according to claim 43 and further comprising heat transfer printing of at least one of said fabric substructures.

Claim 50

A process for producing a warp knitted textile spacer fabric according to claim 43, wherein said warp knitting step comprises forming each of said front and back substructures in needle loops of said ground and stretchable yarns arranged in longitudinal wales and transverse courses and forming each pile yarn of said two sets of pile yarns in successive needle loops which alternate every course between non-corresponding wales of said front and back fabric substructures.

Claim 51

A process for producing a warp knitted textile spacer fabric according to claim 46, wherein said warp knitting step comprises forming the successive needle loops of each pile yarn of said two sets of pile yarns in alternating needle loops arranged alternatingly in spaced wales of successive courses of one of said front and back fabric substructures and intervening needle loops arranged in a common wale of successive courses of the other of said front and back fabric substructures.

Claim 52

A process for producing a warp knitted textile spacer fabric according to claim 47, wherein said spaced wales of said alternating pile yarn needle loops are separated by at least one intervening wale of said one fabric substructure.

Claim 53

A process for producing a warp knitted textile spacer fabric according to claim 48, wherein said warp knitting step comprises knitting one said set of monofilament pile yarns between said front and back fabric substructures in a 1-0, 2-3, 4-5, 3-2 stitch construction and knitting the other said set of monofilament pile yarns between said front and back fabric substructures in a 5-4, 2-3, 0-1, 3-2 stitch construction.

Claim 54

A warp knitted textile spacer fabric according to claim 48, wherein said warp knitting step comprises knitting one said set of monofilament pile yarns between said front and back fabric substructures in a 1-0, 1-2, 2-3, 2-1 stitch construction and knitting the other said set of monofilament pile yarns between said front and back fabric substructures in a 2-3, 2-1, 1-0, 1-2 stitch construction.

Claim 55

A process for producing a warp knitted textile spacer fabric according to claim 48, wherein said warp knitting step comprises knitting one said set of monofilament pile yarns between said front and back fabric substructures in a 1-0, 2-3, 4-5, 3-2 stitch construction and knitting the other said set of monofilament pile yarns between said front and back fabric substructures in a 4-5, 3-2, 1-0, 2-3 stitch construction.

Claim 56

A process for producing a warp knitted textile spacer fabric according to claim 48, wherein one said set of monofilament pile yarns are warp knitted between said front and back fabric substructures in a 1-0, 3-4, 6-7, 4-3 stitch construction and the other said set of monofilament pile yarns are knitted between said front and back fabric substructures in a 6-7, 4-3, 1-0, 3-4 stitch construction.

Claim 57

A process for producing a warp knitted textile spacer fabric according to claim 48, wherein one said set of monofilament pile yarns are warp knitted between said front and back fabric substructures in a 1-0, 4-5, 8-9, 5-4 stitch construction and the other said set of monofilament pile yarns are knitted between said front and back fabric substructures in an 8-9, 5-4, 1-0, 4-5 stitch construction.

Claim 58

A process for producing a warp knitted textile spacer fabric according to claim 47, wherein said spaced wales of said alternating pile yarn needle loops are separated by at least three intervening wales of said one fabric substructure.

Claim 59

A process for producing a warp knitted textile spacer fabric according to claim 47, wherein said spaced wales of said alternating pile yarn needle loops are separated by at least five intervening wales of said one fabric substructure.

Claim 60

A process for producing a warp knitted textile spacer fabric according to claim 47, wherein said spaced wales of said alternating pile yarn needle loops are separated by at least seven intervening wales of said one fabric substructure.

Claim 61

A process for producing a warp knitted textile spacer fabric according to claim 43, wherein said warp knitting step comprises forming said pile segments of said two sets of pile yarns to act cooperatively as a pyramidal system of triangularly related trusses for supporting and maintaining said front and back fabric substructures in compressible spaced parallel relation and for resisting relative shear movement thereof in response to forces exerted in directions generally parallel to said fabric substructures.

Claim 62

A process for producing a warp knitted spacer fabric according to claim 43 and further comprising the step of, prior to said warp knitting step, preparing a respective warp beam of each said set of ground, stretchable and pile yarns and heat transfer printing of at least one set of said ground yarns while in warp sheet form.

Claim 63

A process for producing a warp knitted textile spacer fabric according to claim 43, wherein said warp knitting step comprises knitting each said ground yarn of one of said front and back fabric substructures in a 0-1, 1-1, 3-2, 2-2 stitch construction, knitting each said stretchable yarn of said one fabric substructure in a 2-1, 1-1, 0-1, 1-1 stitch construction, knitting each said body yarn of the other fabric substructure in a 1-1, 3 -2, 2 -2, 0-1 stitch construction, and knitting each said stretchable yarn of said other fabric substructure in a 1-1, 0-1, 1-1, 2-1 stitch construction.

Claim 64

A process for producing a warp knitted spacer fabric of the double needle bar Raschel pile type having characteristics of stretchability, compressibility and resiliency simulative of resilient plastic foam materials and having characteristics of air and moisture permeability substantially enhanced over said foam materials, said process comprising the steps of warp knitting on a double needle bar Raschel knitting machine having at least seven yarn guide bars an at least seven bar spacer fabric comprising front and back stretchable fabric substructures and a pile substructure integrated with an extending between the front and back fabric substructures for maintaining the front and back fabric substructures in spaced parallel relation and being resiliently yieldable for compressibility of the front and back fabric substructures together and subsequent recovery thereof to spaced parallel relation, said knitting steps comprising forming each said fabric substructure by interknitting at least a set of ground yarns and a set of stretchable yarns with one another in a stretchable resilient stitch construction and forming said pile substructure by interknitting at least two sets of monofilament pile yarns with each said fabric substructure in a stitch construction forming pile segments which extend transversely between said fabric substructures in differing angular orientations relative thereto for permitting resilient compressibility of said fabric substructures while resisting relative shear movement of said fabric substructures in directions parallel thereto and knitting a third set of monofilament pile yarns with each said fabric substructure in a chain stitch construction forming pile segments which extend transversely between said fabric substructures.

Claim 65

A process for producing a warp knitted spacer fabric of the double needle bar Raschel pile type having characteristics of stretchability, compressibility and resiliency simulative of resilient plastic foam materials and having characteristics of air and moisture permeability substantially enhanced over said foam materials, said process comprising the steps of warp knitting on a double needle bar Raschel knitting machine having at least seven yarn guide bars an at least seven bar spacer fabric comprising front and back stretchable fabric substructures and a pile substructure integrated with an extending between the front and back fabric substructures for maintaining the front and back fabric substructures in spaced parallel relation and being resiliently yieldable for compressibility of the front and back fabric substructures together and subsequent recovery thereof to spaced parallel relation, said knitting steps comprising forming each said fabric substructure by interknitting at least a set of ground yarns and a set of stretchable yarns with one another in a stretchable resilient stitch construction and forming said pile substructure by interknitting at least two sets of monofilament pile yarns with each said fabric substructure in a stitch construction forming pile segments which extend transversely between said fabric substructures in differing angular orientations relative thereto for permitting resilient compressibility of said fabric substructures while resisting relative shear movement of said fabric substructures in directions parallel thereto and knitting a third set of monofilament pile yarns with each said fabric substructure in a chain stitch construction forming pile segments which extend transversely between said fabric substructures.

Claim 66

A process for producing a warp knitted textile spacer fabric according to claim 60, wherein said warp knitting step comprises forming each pile yarn of said third set of pile yarns in successive needle loops which alternate every course between corresponding wales of said front and back fabric substructures.

Claim 67

A process for producing a warp knitted textile spacer fabric according to claim 61, wherein said warp knitting step comprises knitting said third set of monofilament pile yarns between said front and back fabric substructures in a 1-0, 0-1, 0-1, 1-0 chain stitch construction.

Claim 68

A process for producing a warp knitted textile spacer fabric according to claim 61, wherein said warp knitting step comprises knitting said third set of monofilament pile yarns between said front and back fabric substructures in a 1-0, 0-0, 0-0, 0-1, 1-1, 1-1 chain stitch construction.

Claim 69

A process for producing a warp knitted textile spacer fabric according to claim 61, wherein said warp knitting step comprises forming said pile segments of said three sets of pile yarns to act cooperatively as a pyramidal system of triangularly related trusses for supporting and maintaining said front and back fabric substructures in compressible spaced parallel relation and for resisting relative shear movement thereof in response to forces exerted in directions generally parallel to said fabric substructures.

Claim 70

A process for producing a warp knitted textile spacer fabric according to claim 64, wherein said warp knitting step comprises forming each said triangularly related truss to comprise six pile segments including a pair of pile segments of each of said three sets of pile yarns, said six pile segments extending from six respective spaced-apart needle loops formed in one of said front and back fabric substructures and converging together in six respective plated needle loops of said pile yarns formed in a common course and wale of the other of said front and back fabric substructures.

Claim 71

A process for producing a warp knitted textile spacer fabric according to claim 65, wherein said warp knitting step comprises knitting each said ground yarn of one of said front and back fabric substructures in a 0-1, 1-1, 3-2, 2-2 stitch construction, knitting each said stretchable yarn of said one fabric substructure in a 2-1, 1-1, 0-1, 1-1 stitch construction, knitting each said body yarn of the other fabric substructure in a 1-1, 3-2, 2-2, 0-1 stitch construction, and knitting each said stretchable yarn of said other fabric substructure in a 1-1, 0-1, 1-1, 2-1 stitch construction.

Claim 72

A process for producing a warp knitted textile spacer fabric according to claim 60, wherein said warp knitting step comprises knitting each said ground yarn of one of said front and back fabric substructures in a 0-1, 1-1, 3-2, 2-2 stitch construction, knitting each said stretchable yarn of said one fabric substructure in a 2-1, 1-1, 0-1, 1-1 stitch construction, knitting each said body yarn of the other fabric substructure in a 1-1, 3-2, 2-2, 0-1 stitch construction, and knitting each said stretchable yarn of said other fabric substructure in a 1-1, 0-1, 1-1, 2-1 stitch construction.

Claim 73

A process for producing a warp knitted spacer fabric of the double needle bar Raschel pile type having characteristics of stretchability, compressibility and resiliency simulative of resilient plastic foam materials and having characteristics of air and moisture permeability substantially enhanced over said foam materials, said process comprising the steps of warp knitting on a double needle bar Raschel knitting machine having at least six yarn guide bars an at least six bar spacer fabric comprising front and back stretchable fabric substructures and a pile substructure integrated with and extending between the front and back fabric substructures for maintaining the front and back fabric substructures in spaced parallel relation and being resiliently yieldable for compressibility of the front and back fabric substructures together and subsequent recovery thereof to spaced parallel relation, said knitting steps comprising forming each said fabric substructure by interknitting at least a set of ground yarns and a set of stretchable yarns with one another in a stretchable resilient stitch construction having needle loops of said ground and stretchable yarns arranged in longitudinal wales and transverse courses and forming said pile substructure by interknitting at least two sets of monofilament pile yarns with each said fabric substructure in a stitch construction forming pile segments which extend transversely between said fabric substructures in differing angular orientations relative thereto for permitting resilient compressibility of said fabric substructures while resisting relative shear movement of said fabric substructures in directions parallel thereto, said interknitting said pile yarns comprising forming said pile segments of said two sets of pile yarns to act cooperatively as a pyramidal system of triangularly related trusses for supporting and maintaining said front and back fabric substructures in compressible spaced parallel relation and for resisting relative shear movement thereof in response to forces exerted in directions generally parallel to said fabric substructures by forming each said triangularly related truss to comprise four pile segments including a pair of pile segments of each of said two sets of pile yarns, said four pile segments extending from four respective spaced-apart needle loops formed in one of said front and back fabric substructures and converging together in four respective plated needle loops of said pile yarns formed in a common course and wale of the other of said front and back fabric substructures.

Claim 74

A process for producing a warp knitted spacer fabric of the double needle bar Raschel pile type having characteristics of stretchability, compressibility and resiliency simulative of resilient plastic foam materials and having characteristics of air and moisture permeability substantially enhanced over said foam materials, said process comprising the steps of warp knitting on a double needle bar Raschel knitting machine having at least six yarn guide bars an at least six bar spacer fabric comprising front and back stretchable fabric substructures and a pile substructure integrated with and extending between the front and back fabric substructures for maintaining the front and back fabric substructures in spaced parallel relation and being resiliently yieldable for compressibility of the front and back fabric substructures together and subsequent recovery thereof to spaced parallel relation, said knitting steps comprising forming each said fabric substructure by interknitting at least a set of ground yarns and a set of stretchable yarns with one another in a stretchable resilient stitch construction having needle loops of said ground and stretchable yarns arranged in longitudinal wales and transverse courses and forming said pile substructure by interknitting at least two sets of monofilament pile yarns with each said fabric substructure in a stitch construction forming pile segments which extend transversely between said fabric substructures in differing angular orientations relative thereto for permitting resilient compressibility of said fabric substructures while resisting relative shear movement of said fabric substructures in directions parallel thereto, said interknitting said pile yarns comprising forming said pile segments of said two sets of pile yarns to act cooperatively as a pyramidal system of triangularly related trusses for supporting and maintaining said front and back fabric substructures in compressible spaced parallel relation and for resisting relative shear movement thereof in response to forces exerted in directions generally parallel to said fabric substructures by forming each said triangularly related truss to comprise four pile segments including a pair of pile segments of each of said two sets of pile yarns, said four pile segments extending from four respective spaced-apart needle loops formed in one of said front and back fabric substructures and converging together in four respective plated needle loops of said pile yarns formed in a common course and wale of the other of said front and back fabric substructures.