[0001] This application claims priority from Australian provisional application 2021901427 filed on 13 May 2021 , the entire contents of which are incorporated herein by this reference.

Technical Field

[0002] The present invention relates to a knitted fabric. The fabric has been specifically designed for use as solar shade and/or hail protection and/or wind protection cloth and will herein be generally described in this context. The fabric may be utilised in temporary, semi-permanent or permanent structure applications.

[0003] It is to be appreciated, however, that the fabric may be utilised in other applications besides those referred to above.

Background of Invention

[0004] Existing knitted fabrics, particularly those designed for use as shade cloth, are most commonly manufactured on warp knitting machines, utilising structures based on net knitting technology.

[0005] Such fabrics are typically manufactured from monofilaments of high-density polyethylene (HDPE), split film high-density polyethylene yarns (or fibres) or polypropylene.

[0006] Nets typically comprise chains of knitted loops in the warp direction that are interconnected by yarns or fibres laid-in around the knitted loops and lying in the weft direction. In the manufacture of shade cloth, it is common to introduce yarns in the weft direction by knitting them into the loop structure and having relatively large movements across several needles in the underlap phase of the knitting cycle. In knitting terminology generic shade cloth structures can be described as open loop pillar stitch on a front guide bar accompanied by knitted or laid-in yarns with underlaps of several (say 3 to 5) needle spaces.

[0007] The multiple number of yarns in the weft direction, compared to the single vertical underlap of the pillar stitch lead to considerable imbalance in the strength and load carrying capacity of the fabric in the warp and weft directions, which is undesirable, particularly in the context of shade cloth. Often, the warp direction strength will be as low as 25% of the strength in the weft direction, and this can result in failure of the fabric when in tension in the warp direction.

[0008] Australian Patent Application 2016374650 describes a knitted fabric which addresses the above shortcomings by providing a plurality of parallel chains of knitted loops, with each chain of knitted loops formed from a respective yarn, and with the parallel chains of knitted loops extending in the warp or vertical direction. The fabric also includes a plurality of weft yarns, with each weft yarn connected to and extending across at least two adjacent chains of knitted loops. Each chain of knitted loops is also associated with at least one respective yarn that is connected to and intertwines along the chain of knitted loops. While such a knitted fabric provides improvements, there is still a need to provide further stability under tension in the weft and warp direction. Attempts have been made to run reinforcing yarns with little success to date.

[0009] The applicant is aware of previous attempts at running reinforcing yarns of varying materials down chain stitches so as to act as a tear resistant component, and to provide the desired stability. In such arrangements, the reinforcing yarns lap around the needle loop at each course, and little if any further dimensional stability increase is obtained. Further, as reinforcing yarns tend to be of a different material to structural yarns, great difficulty is encountered in combining the two different materials in a single fabric so as to extract a commercially viable improvement, due to the variation in physical properties between the materials.

[0010] It would therefore be desirable to provide a fabric suitable for any or all of a solar shade, a hail protection cloth and a wind protection cloth that addresses the above shortcomings, and which has enhanced mechanical properties when compared to existing shade cloth fabrics. Particularly, but not exclusively, it would be desirable to provide a fabric suitable for use as a shade cloth that has an improved load bearing capacity in the warp and weft direction, and improved balance when comparing strengths in the warp and weft directions, whilst providing high levels of opacity (and, thus, protection from UV radiation) expected of shade cloth fabrics. Likewise, it would be desirable to provide a hail and/or wind protection cloth that addresses the above shortcomings. Summary of Invention

[0011] As previously noted, the mere inclusion of a reinforcing yarn in a knitted fabric does not result in the desired improvement in fabric performance. Further, replacing yarn material such as high-density polyethylene (HDPE) with a stronger material such as carbon fibre significantly increases the cost of the fabric and compromises certain fabric properties such as compressive strength. The reinforcement of a knitted fabric requires careful consideration of the knit pattern, and of the material used. Australian Patent 2016374650 provides a knitted fabric with reinforcing yarns, however merely replacing the reinforcing yarns of the application with metallic based wire was found to not provide the desired improvements in strength, tear resistance, and load bearing properties. Rather, the direct replacement of any of the yarns with a reinforcing wire increased cost and weight of the fabric, both of which outweighed any benefit provided by the wire.

[0012] As noted above, where a reinforcing yarn is to be of a different material to the structural yarns comprising the body of the fabric, great difficulty is encountered in combining the two in a single fabric due to the variation in physical properties. It is important, and difficult to ensure the performance properties of a reinforcing wire is balanced with the body of a knitted fabric. Without this balance, the wire and/or fabric component will be load bearing, with the other component not adding a significant benefit to the fabric performance.

[0013] In seeking commercially viable improvements in the fabric’s properties, the Applicant has undertaken rigorous research and testing to determine how to incorporate a wire element into a knitted fabric design so as to obtain an acceptable balance between wire performance properties and the changes in properties of the body of the fabric.

[0014] According to a broad aspect of the present invention, there is provided a knitted fabric. The fabric includes a plurality of parallel chains of knitted loops, with each chain of knitted loops formed from a respective yarn, and with the parallel chains of knitted loops extending in the warp or vertical direction. The fabric also includes a plurality of weft yarns, with each weft yarn connected to and extending across at least two adjacent chains of knitted loops. A plurality of the chains of knitted loops are also associated with at least one intertwining yarn, with each intertwining yarn being intertwined with and extending along and / or across the chains of knitted loops, wherein the at least one intertwining yarn is a wire element.

[0015] In one embodiment, each chain of knitted loops is knitted with yarns that traverse across several needle spaces before being knitted on an adjacent needle to form long underlaps or weft yarns. A plurality of chains of knitted loops are also associated with a pair of intertwining yarns, with each yarn of the pair being connected to and extending along the associated chain/s of knitted loops. In one form, each pair of intertwining yarns includes a first yarn connected to the respective chain of knitted loops, and a second yarn connected to the chain of knitted loops in a mirror image arrangement to that of the first yarn about the approximate centre line of the respective chain of knitted loops. In an alternative embodiment where the pair of intertwining yarns are not symmetrically arranged in a mirror image arrangement along the warp direction, a first yarn may be intertwined with a respective chain of knitted loops in a warp or weft direction, and a second yarn may be intertwined in a non-symmetrical / asymmetrical configuration, generally perpendicular or angled to the first yarn. In a further alternative embodiment, only one yarn may be intertwining. The intertwining yarns can be considered as load bearing yarns in the warp direction and across the width of the fabric. That is, they enhance the load bearing capacity of the fabric in the warp and width direction, which is a highly desirable feature of the invention.

[0016] Each of the chains of knitted loops, weft yarns and intertwining yarns may be manufactured from at least one of a monofilament, multi-filament and split film. In one form, each of the chains of knitted loops, weft yarns and intertwining yarns is manufactured from a monofilament.

[0017] Each of the chains of knitted loops, and the weft yarns may be manufactured from at least one of nylon, polypropylene, polyester, ultra-high molecular weight high- density polyethylene (UHMWHDPE) and high-density polyethylene (HDPE), or other engineered fibres. In this respect, the knitted loops and weft yarns may be manufactured from a synthetic material not limited to those listed above. In one form, each of the chains of knitted loops, and weft yarns is manufactured at least substantially from high-density polyethylene (HDPE). [0018] The intertwining yarns may be manufactured from at least one of a metal, a metal compound, and a metal-polymer composite. In one form, at least one, or both of the intertwining yarns is manufactured from steel. The steel may be stainless steel, annealed AISI 316L, which has been found to provide suitable ductility and weathering durability.

[0019] It is envisaged that the fabric may be manufactured on a compound or latch needle warp knitting machine, with four guide bars of the knitting machine being utilised to manufacture the fabric. In such an arrangement, the four guide bars may include a front (or first) guide bar, a second guide bar, a third guide bar and a fourth guide bar that may follow the following knitting movements to manufacture the fabric:

-front guide bar: 0-1/1 -0//;

-second guide bar: 1 -0/4-5//;

-third guide bar: 0-0/1 -1/1 -1/0-0//; and

-fourth guide bar: 1 -1 /0-0/0-0/1 -1 //.

[0020] In an alternative embodiment, the front (or first) guide bar, the second guide bar, the third guide bar and the fourth guide bar may follow the following knitting movements to manufacture the fabric:

- front guide bar: 0-1/1 -0// (full thread);

-second guide bar: 1 -0/4-5// (full thread);

-third guide bar: 0-0/1 -1/2-2/3-3/4-4/5-5-/6-6/7-7/8-8/7-7-/6-6/5-5/4-4/3-3/2-2/1 - 1// (1 in/2out); and

-fourth guide bar: 8-8/7-7/6-6/5-5/4-4/3-3/2-2/1 -1 /0-0-/1 -1 /2-2/3-3/4-4/5-5/Q-6/7- 7// (1 in/2 out). [0021] In a further alternative embodiment, the front (or first) guide bar, the second guide bar, the third guide bar and the fourth guide bar may follow the following knitting movements to manufacture the fabric:

-front guide bar: 0-1 /1 -0;

-second guide bar: 1 -0/4-5;

-third guide bar: 0-0/0-0/0-0/0-0/1 -1/1 -1/1 -1/1 -1//; (1 in/2 out) and -fourth guide bar: 1-1/1-1/1-1/1-1 /0-0/0-0/0-0/0-0// (1 in/2 out).

[0022] In a further alternative embodiment, the front (or first) guide bar, the second guide bar, the third guide bar and the fourth guide bar may follow the following knitting movements to manufacture the fabric:

-front guide bar: 0-1 /1 -0;

-second guide bar: 1 -0/4-5;

-third guide bar: 0-0/4-4// (1 in/2 out); and

-fourth guide bar: 0-0/0-0/0-0/0-0//1 -1/1 -1/1 -1/1-1// (1 in/2 out).

[0023] It is to be appreciated that other knitting patterns can be used. In one alternative form, each intertwining yarn is provided at an angle to the warp or vertical direction, and each yarn may be angled in a non-symmetrical manner relative to the other.

[0024] In use, the front guide bar supplies the yarn for the chain of knitted loops, the second guide bar supplies the weft yarn, and the third and fourth guide bars supply the first and second intertwining yarns, respectively.

[0025] It is envisaged that the fabric according to the present invention would be particularly suitable for use as any one or more of a solar shade, hail and wind cloth protection fabric. The reinforcing fibres provide the fabric with increased versatility, as it provides enhanced load bearing capabilities, dimensional stability, lower creep under load, fire repellence, electrical conductivity and an extended useful life.

[0026] The thickness of each of the warp yarns, weft yarns / knitted loop yarns and at least one of the intertwining yarns may be selected as desired. The Applicant envisages a thickness somewhere between approximately 300 and 1 ,000 denier, with a thickness of approximately 400 to 600 denier currently being envisaged by the Applicant as being suitable for use in at least one embodiment of the invention. The diameter of the at least one intertwining yarn wire is envisaged to be 0.15 to 0.25 mm.

[0027] In one or more embodiments of the invention, at least some of the intertwining yarns may be knitted or tied to their respective chains of knitted loops. Knitting or tying of the intertwining yarns to the chains of knitted loops may be provided intermittently along the chain of knitted loops.

[0028] In some embodiments, it may be desirable to include additional warp yarns in the fabric, with the additional warp yarns provided in an interwoven configuration within the fabric by one or more of a selective miss-lap technique and evasive laying- in technique.

Brief Description of Drawings

[0029] It will be convenient to hereinafter describe preferred embodiments of the invention with reference to the accompanying drawings. The particularity of the drawings is to be understood as not limiting the preceding broad description of the invention.

[0030] Figure 1 is a schematic view of a knitted fabric according to one embodiment of the present invention. The matrix of dots represent knitted loops, vertical rows in the warp or machine direction, and horizontal rows in the weft or lateral direction. The fabric components have been separated out and are shown in a side-by-side arrangement for clarity. In practice, loops would be formed in each column and row.

[0031] Figure 2 is a schematic view of a knitted fabric according to a second embodiment of the present invention. The matrix of dots represent knitted loops, vertical rows in the warp or machine direction, and horizontal rows in the weft or lateral direction. The fabric components have been separated out and are shown in a side-by- side arrangement for clarity. In practice, loops would be formed in each column and row.

[0032] Figure 3 is a schematic view of a knitted fabric according to a third embodiment of the present invention. The matrix of dots represent knitted loops, vertical rows in the warp or machine direction, and horizontal rows in the weft or lateral direction. The fabric components have been separated out and are shown in a side-by- side arrangement for clarity. In practice, loops would be formed in each column and row.

[0033] Figure 4 provides a physical embodiment of a material according to Figure 1.

Detailed Description

[0034] Referring to Figure 1 , there is depicted a knitted fabric 10 suitable for use as a shade cloth (and/or a wind protection cloth and/or hail a protection cloth), with enhanced load bearing properties. As stated previously, the fabric components have been separated out and are shown in a side-by-side arrangement for clarity.

[0035] The fabric 10 includes a plurality of parallel chains 12 of knitted loops, with only one chain 12 being shown. The chains 12 are arranged parallel to one another and extend in the warp direction Y-Y. In the illustrated embodiment, each chain 12 is manufactured from a respective monofilament yarn of high-density polyethylene, although other suitable yarn materials may be used instead. The high-density polyethylene is envisaged to have the following properties at a thickness of approximately 600 Denier: Tensile strength - 40-60N, elongation at break - 15-25%. In alternative embodiments, the chains may be made of any suitable material/yarns.

[0036] The fabric 10 also includes a plurality of weft yarns 14, although only one such weft yarn is shown. Each of the weft yarns 14 is manufactured from a respective monofilament yarn of high-density polyethylene, although other suitable yarn materials may be used instead. The high-density polyethylene is envisaged to have the following properties at a thickness of approximately 600 Denier: Tensile strength - 40-60N, elongation at break - 15-25%.

[0037] Each weft yarn 14 extends in the weft direction X-X, and extends about or through at least two adjacent chains 12 of knitted loops. Indeed, the fabric may be designed such that each weft yarn 14 extends about or through any practical number of adjacent chains 12. [0038] Each chain 12 of knitted loops is associated with a pair of yarns 16, 18. Each yarn 16, 18 is connected to and intertwines along the chain 12 of knitted loops. It is to be appreciated that the yarn 18 is intertwined with the chain 12 in a symmetrical / mirror image arrangement when compared to yarn 16 about the approximate longitudinal centre line of the chain 12. That is, yarn 18 is underlapped in the opposite direction to yarn 16. It can be seen that the yarns 16, 18 provide an enclosure around two successive knitted loops, providing restriction to the stretching of the loops of the chain 12 when under tension, as well as contributing load bearing capacity to the fabric 10 in the warp direction Y-Y. The provision of yarns about pillar stitch columns (such as those of chains 12) is an element that the Applicant is aware of having been used in net constructions, including laces. However, in those constructions, connection of the yarns to the pillar stitch occurs at each course, with the intention of “hiding” the yarn until moved several needle spaces during the underlap phase of a knitting cycle to produce horizontal yarn elements to yield the net structure. Relatively little mechanical benefit is obtained from these yarns in the vertical (or warp) direction. The Applicant is also aware of previous attempts at running reinforcing yarns down chain stitches so as to act as a tear resistant component. In such arrangements, the reinforcing yarns lap around the needle loop at each course, and, unlike the present invention, little if any dimensional stability increase is obtained.

[0039] The Applicant has found that the intertwining yarns 16, 18 of the illustrated embodiment gives the fabric enhanced dimensional stability relative to the embodiments of Figures 2 and 3, increased load bearing characteristics and warp reinforcement. The yarns 16, 18 of the illustrated embodiment are manufactured from stainless steel, annealed AISI 316L to provide the previously mentioned enhancements. The stainless steel is envisaged to have the following properties at a diameter of approximately 0.20mm: Elastic Modulus- 200GPa 29 x 10 ^L 6 psi, Brinell hardness of 170-230, Elongation at break - 35-50%, and a Poisson’s Ratio of 0.28.

[0040] It is envisaged by the Applicant, that the fabric of Figure 1 comprises a HDPE/Stainless wire ratio of generally 85%/15%. In this aspect, the fabric is envisaged to have a weight of approximately 500gsm. In alternative embodiments, the yarns 16, 18 may be of any other suitable steel, or any other suitable yarn materials may be used instead, such as a metal, or a metal compound, or a metal-polymer composite, or any one of the yarns may be a respective monofilament of high density polyethylene. In this respect, the yarns 16, 18 may be of different materials having different properties.

[0041] The fabric 10 is manufactured on a latch needle warp knitting machine, with four guide bars of the knitting machine being utilised to manufacture the fabric, and each introducing a yarn into the fabric structure. In such an arrangement, the four guide bars may include a front (or first) guide bar 20, a second guide bar 22, a third guide bar 24 and a fourth guide bar 26 that follow the following knitting movements to manufacture the fabric 10:

-front guide bar: 0-1/1 -0;

-second guide bar: 1 -0/4-5;

-third guide bar: 0-0/0-0/0-0/0-0/1 - 1/1 -1/1 -1/1-1 ; (1 in/2 out) and

-fourth guide bar: 0-0/0-0/0-0/0-0/1 -1/1 -1/1 -1/1 -1 (1 in/2 out)

[0042] In use, the front guide bar 20 supplies the yarn for the chain 12 of knitted loops, the second guide bar supplies the weft yarn 14, and the third and fourth guide bars supply the first and second intertwined yarns 16, 18, respectively.

[0043] The front guide bar 20 carries yarn of chains 12 around the needle hooks (overlap) to produce vertical rows of loops in a configuration known as open loop pillar stitch. On the successive course, the traverse around the needle hooks is in the opposite direction. There is no underlap movement. The second guide bar 22 carries the weft yarn 14 around the needle hooks (overlap) and then across the back of the needles for several needle spaces during the underlap part of the knitting cycle. It is to be appreciated that the size of these underlaps may be varied to manipulate the weight of the fabric 10 and its horizontal stability. The second guide bar 22 enters and exits between the needles during the overlap part of the knitting cycle, thus being joined to the knitted loops as “laid-in” yarns.

[0044] The third guide bar 24, and the fourth guide bar 26 do not fully thread the intertwined yarns 16, 18 into the fabric 10. This can be seen in Figure 4. Rather, the guide bar operates in a ‘1 in, 2 out’ configuration, whereby the following pattern is repeated: one needle insertion is made, then two needle insertions are skipped. In this respect, not all yarn threads 12, 14 are wrapped or threaded by the intertwining yarns 16, 18. In alternative embodiments, the knit pattern of intertwining yarns 16, 18 can be amended to any suitable pattern, for example, 1 in, 1 out, or 1 in and 3 out.

[0045] The third guide bar 24 and the fourth guide bar 26 overlap each other. In this embodiment, the third guide bar 24 does not overlap itself. The third guide bar 24 carries yarn 16 making no underlap movement for one or more knitting cycles as well as no overlaps, and then moves one needle space of underlap before repeating the miss-lap cycle and returning to its original position. It is to be appreciated that the fourth guide bar 26 performs the same role with yarn 18 as the third guide bar 24 does with yarn 16 but makes underlap movements in the opposite direction to the third guide bar 24. The yarns 16, 18 introduced by the third and fourth guide bars 24, 26, respectively, provide an enclosure/or extend over/around/through approximately four successive knitted loops of yarn 12, per guide bar 24, 26 movement, providing restriction to the stretching of the loops under tension as well as contributing fabric load bearing capacity in their own right. Careful balancing of the run-ins of the guide bars, 20, 22, 24, 26 optimizes the load bearing capacity of the fabric 10 in both vertical (warp) and horizontal (weft) directions.

[0046] Thus, it can be appreciated that the first and second guide bars 20, 22 provide the two-dimensional structure of the fabric 10; whereas the third and fourth guide bars 24, 26 supply yarns 16, 18, respectively, enclose the knitted loops, restricting their ability to deform under load, and provide additional load carrying capacity and stretch resistance. It is envisaged that the yarns 16, 18 may, instead, be replaced by yarns from a single guide bar.

[0047] The interaction of at least three (and preferably four) yarn components is integral to the success of this invention. The four yarns have separate and specific roles namely: chains of loops 12 formed vertically and weft yarn 14 which hold the horizontally oriented components to form the basic two dimensional structure, with additional yarns 16, 18 constraining each knitted chain 12 from distortion under load and adding vertical strength. The interactions generated by the enclosing of the knitted cells over more than one course by two opposed yarns 16, 18 running up the chains 12 gives controllable load sharing and movement limitation in the knitted loops, and tightens the grip of the loops on the horizontal laid-in yarns. Balance between these components is achieved by control of run-in to optimize outcomes. [0048] The denier of the yarns of the chain 12, and the weft yarns 14 and the diameter of the intertwining yarns 16, 18 may be selected as desired. As stated previously, the applicant envisages a thickness somewhere between approximately 300 and 1 ,000 denier for the yarns of the chain 12 and weft yarns, with a thickness of approximately 400 to 700 denier currently being envisaged by the applicant as being suitable for use in at least the illustrated Figure 1 embodiment of the invention. The Applicant envisages a diameter of the intertwining yarns 16, 18 being somewhere between approximately 0.15mm to 0.25mm, with a diameter of approximately 0.20mm being suitable for use in at least the illustrated Figure 1 embodiment of the invention.

[0049] The Applicant has established during trials of the fabric 10 that the fabric strength in the warp direction is slightly stronger than that in the weft direction. In this respect, the configuration of the yarns in fabric 10 of Figure 1 provides warp reinforcement, enhanced dimensional stability and load bearing characteristics. This is considered by the Applicant to be unique to their invention, at least in the context of solar shade cloth (as well as hail and/or wind protection cloth), and is as a result of improved overall strength in the warp direction rather than any decrease in weft direction strength. This improved warp direction strength and more balanced strength in the warp and weft directions is highly desirable in the context of shade cloth, thus making the cloth more versatile than previous embodiments, by giving it enhanced load bearing capability. Moreover, it clearly distinguishes the Applicant’s fabric 10 from that of competitor products that lack load bearing capabilities, warp direction strength, and strength balance in the warp and weft directions. The Applicant’s fabric 10 is not only strong and balanced, it also desirably provides high levels of opacity (and, thus, protection from UV radiation) expected of shade cloth fabrics.

[0050] Referring to Figure 2, there is depicted a knitted fabric 110 suitable for use as shade cloth (and/or wind protection and/or hail protection cloth) with enhanced load bearing properties. Similar to Figure 1 , the fabric components have been separated out and are shown in a side-by-side arrangement for clarity.

[0051] The fabric 110 includes the same plurality of parallel chains 112 of knitted loops, with only one chain 112 being shown. The chains 112 are arranged parallel to one another and extend in the warp direction Y-Y. In the illustrated embodiment, each chain 112 is manufactured from a respective monofilament yarn of high-density polyethylene, although other suitable yarns may be used instead.

[0052] The fabric 110 also includes a plurality of weft yarns 114, although only one such weft yarn is shown. Each of the weft yarns 114 is manufactured from a respective monofilament yarn of high-density polyethylene, although other suitable yarns may be used instead.

[0053] The high-density polyethylene of the chains 112 and weft yarns 114 is envisaged to have the following properties at a thickness of approximately 600 Denier: Tensile strength - approximately 40-60N, elongation at break - approximately 15-25%.

[0054] Each weft yarn 114 extends in the weft direction X-X and extends about or through at least two adjacent chains 112 of knitted loops. Indeed, the fabric may be designed such that each weft yarn 114 extends about or through any practical number of adjacent chains 112.

[0055] Each chain 112 of knitted loops is associated with a pair of generally biaxially arranged yarns 116, 118, generally provided at an angle to the warp direction Y-Y. Yarns 116, 118 are shown in an overlaid arrangement. Each yarn 116, 118 is connected to and intertwines along the chain 112 of knitted loops. It can be seen that the yarn 118 is provided in a symmetrical and mirror image arrangement when compared to yarn 116. Each yarn 116, 118 may be provided such that it intertwines any practical number of chains. The yarns 116, 118 can be considered as load bearing yarns in the warp and weft direction due to their general biaxial (angled) configuration. That is, they enhance the load bearing capacity of the fabric in the warp and weft/vertical direction, which is a highly desirable feature of the invention. In alternative embodiments, the intertwining yarns 116, 118 may be arranged at an angle to the warp or vertical direction other than that shown in Figure 2, and the yarns 116, 118 may not be arranged in a symmetrical mirror image configuration.

[0056] The Applicant has found that the intertwining yarns 116, 118 of the illustrated embodiment of Figure 2 give the fabric the best balance of tensile strength, tear resistance and impact resistance, relative to the embodiments of Figures 1 and 3. The yarns 116, 118 of the illustrated embodiment are manufactured from stainless steel, annealed AISI 316L to provide the previously mentioned enhancements. The stainless steel is envisaged to have the following properties at a diameter of approximately 0.20mm: Elastic Modulus- 200GPa 29 x 10 ^L 6 psi, Brinell hardness of 170-230, Elongation at break - 35-50%, and a Poisson’s Ratio of 0.28.

[0057] It is envisaged by the applicant, that the fabric of Figure 2 comprises a HDPE/Stainless wire ratio of generally 80%/20%. In this aspect, the fabric 110 is envisaged to have a weight of approximately 540gsm. In alternative embodiments, the yarns 116, 118 may be of any other suitable steel, or any other suitable yarn materials may be used instead, such as a metal, or a metal compound, or a metal-polymer composite, or any one of the yarns may be a respective monofilament of high density polyethylene. In this respect, the yarns 116, 118 may each be of a different material and may each have different properties to the other. For example, yarn 116 may be a high-density polyethylene, and yarn 118 may be a stainless-steel wire.

[0058] The fabric 110 is manufactured on a compound needle warp knitting machine, with four guide bars of the knitting machine being utilised to manufacture the fabric, and each introducing a yarn into the fabric structure. In such an arrangement, the four guide bars may include a front (or first) guide bar 210, a second guide bar 212, a third guide bar 214 and a fourth guide bar 216 that follow the proceeding knitting movements to manufacture the fabric 110:

- front guide bar: 0-1/1 -0//;

- second guide bar: 1 -0/4-5//;

- third guide bar: 0-0/1 - 1 /2-2/3-3/4-4/5-5-/6-6/7-7/8-8/7-7-/6-6/5-5/4-4/3-3/2-2/1 -

1//; (1 in/2 out threading) and

- fourth guide bar: 8-8/7-7/6-6/5-5/4-4/3-3/2-2/1 -1 /0-0-/1 -1 /2-2/3-3/4-4/5-5/6-6/7-

7//. (1 in/2 out threading).

[0059] In use, the front guide bar 210 supplies the yarn for the chain 120 of knitted loops, the second guide bar supplies the weft yarn 140, and the third and fourth guide bars supply the first and second intertwined yarns 160, 180, respectively.

[0060] Similar to the guide bar configuration of Figure 1 , the front guide bar 210 carries yarn of chains 112 around the needle hooks (overlap) to produce vertical rows of loops in a configuration known as open loop pillar stitch. On the successive course, the traverse around the needle hooks is in the opposite direction. There is no underlap movement. The second guide bar 212 carries the weft yarn 114 around the needle hooks (overlap) and then across the back of the needles for several needle spaces during the underlap part of the knitting cycle. It is to be appreciated that the size of these underlaps may be varied to manipulate the weight of the fabric 1 10 and its horizontal stability. The second guide bar 212 enters and exits between the needles during the overlap part of the knitting cycle, thus being joined to the knitted loops as “laid-in” yarns.

[0061] The third guide bar 214, and the fourth guide bar 216 do not fully thread the intertwined yarns 116, 118 into the fabric 110. Rather, the guide bar operates in a ‘1 in, 2 out’ configuration, whereby the following pattern is repeated: one needle insertion is made, then two needle insertions are skipped. In this respect not all yarn threads 12, 14 are wrapped or threaded by the intertwining yarns 16, 18. In alternative embodiments, the knit pattern of intertwining yarns 16, 18 can be amended to any suitable pattern, for example, 1 in, 1 out, or 1 in and 3 out.

[0062] The third guide bar 214 carries yarn 116 making an underlap movement for one or more knitting cycles, moves one needle space, then makes an overlap. This is repeated in the angled direction for 8 needle movements, after which the movement direction is reversed. It is to be appreciated that the fourth guide bar 216 performs the same role with yarn 118 as the third guide bar 214 does with yarn 116 but makes underlap and overlap movements in the opposite direction to the third guide bar 214.

[0063] The yarns 116, 118 introduced by the third and fourth guide bars 214, 216, respectively, extend over at least four successive knitted loops of the first guide bar 210 shown in the drawings between intersections. The number of loops the yarns 116, 118 extend over can be varied to provide different material properties. This intermittent intersection of yarns 116 and 118 provides enhanced tensile strength, tear resistance, impact resistance, and enhanced load bearing capacity, whilst also allowing the fabric 110 to remain relatively flexible. Careful balancing of the run-ins of the guide bars, 210, 212, 214, 216 optimizes the tensile strength, tear resistance, impact strength and load bearing capacity of the fabric 110 in both vertical (warp) and horizontal (weft) directions.

[0064] Thus, the front and second guide bars 210, 212 provide the two-dimensional structure of the fabric 110; whereas the third and fourth guide bars 214, 216 supply yarns 116, 118, respectively, enclose the knitted loops, restricting their ability to deform under load, and providing additional load carrying capacity, stretch resistance, and impact resistance. It is envisaged that the yarns 116, 118 may, instead, be replaced by yarns from a single guide bar.

[0066] The interactions generated by the enclosing of the knitted cells over more than one course by two opposed yarns 1 16, 118 biaxially running up the chains 12 gives controllable load sharing and movement limitation in the knitted loops, and tightens the grip of the loops on the horizontal laid-in yarns. Balance between these components is achieved by control of run-in to optimize outcomes. It is to be appreciated that intertwining yarns 116, 118 may provide an enclosure around any number of successive knitted loops generated by the first guide bar 210, however varying the movements of guide bars 214, 216 will vary the reinforcing properties of the intertwining yarns 116, 118.

[0066] The denier of the yarns of the chain 1 12, and the weft yarns 114 and the diameter of the intertwining yarns 116, 118 may be selected as desired. As stated previously, the applicant envisages a thickness somewhere between approximately 300 and 1 ,000 denier for the yarns of the chain 12 and weft yarns, with a thickness of approximately 400 to 700 denier currently being envisaged by the Applicant as being suitable for use in at least the illustrated Figure 2 embodiment of the invention. The Applicant envisages a diameter of the intertwining yarns 116, 118 being somewhere between approximately 0.15mm to 0.25mm. The Applicant has found a denier of 600D for yarns 112 and 114 and a diameter of 0.20m of yarns 116, 118 to be suitable for use in at least the illustrated Figure 2 embodiment of the invention.

[0067] The Applicant has established during trials of the fabric 110 that the fabric tensile strength, tear resistance and impact resistance is enhanced, and relative to the embodiments of Figures 1 and 3 to be balanced. This is considered by the Applicant to be unique to their invention, at least in the context of solar shade cloth (as well as hail and/or wind protection cloth) and is as a result of improved overall strength in the warp and weft direction. This improved bi-directional and balanced strength in the warp and weft directions is highly desirable in the context of shade cloth, thus making the cloth more flexible than other embodiments of the invention, and also more versatile than the prior art, by giving the fabric enhanced load bearing capability, whilst maintaining other desirable shade cloth features. Moreover, it clearly distinguishes the Applicant’s fabric 110 from competitor products that lack the same load bearing capabilities and biaxial strength and balance. The Applicant’s fabric 110 of Figure 2 is not only strong and balanced, it also desirably provides high levels of opacity (and, thus, protection from UV radiation) expected of shade cloth fabrics.

[0068] Referring to Figure 3, there is depicted a knitted fabric 310 suitable for use as shade cloth (and/or wind protection and/or hail protection cloth). Similar to Figures 1 and 2, the fabric components have been separated out and are shown in a side-by- side arrangement for clarity.

[0069] The fabric 310 includes the same plurality of parallel chains 312 of knitted loops, with only one chain 312 being shown. The chains 312 are arranged parallel to one another and extend in the warp direction Y-Y. The fabric 310 also includes a plurality of weft yarns 314, although only one such weft yarn is shown. Each weft yarn 314 extends in the weft direction X-X and extends about or through at least two adjacent chains 312 of knitted loops. Indeed, the fabric 310 may be designed such that each weft yarn 314 extends about or through any practical number of adjacent chains 312.

[0070] In the illustrated embodiment, each chain 312 and weft yarn 314 is manufactured from a respective monofilament yarn of high-density polyethylene, although other suitable yarns may be used instead. The high-density polyethylene is envisaged to have the following properties at a thickness of approximately 600 Denier: Tensile strength - 40-60N, elongation at break - 15-25%.

[0071] Each chain 312 of knitted loops is associated with a pair of yarns 316, 318 generally arranged perpendicular to each other. Each yarn 316, 318 is connected to and intertwines along the chain 312 of knitted loops. Each yarn 316, 318 may be provided such that it intertwines any practical number of chains. The yarns 316, 318 can be considered as load bearing yarns in the warp direction and weft direction. That is, they enhance the load bearing capacity of the fabric in both the warp and weft direction, which is a highly desirable feature of the invention. The yarns 316, 318 are an example of an asymmetrical arrangement.

[0072] The Applicant has found that the intertwining yarns 316, 318 of the illustrated embodiment of Figure 3 give the fabric the highest level of stiffness, and lowest level of elongation relative to the embodiments of Figures 1 and 2. Similar to the fabrics of Figures 1 and 2, yarns 316, 318 of the illustrated embodiment are manufactured from stainless steel so as to form stainless steel wires, annealed AISI 316L, to provide the previously mentioned enhancements. The stainless steel is envisaged to have the following properties at a diameter of approximately 0.20mm: Elastic Modulus- 200GPa 29 x 10 ^L 6 psi, Brinell hardness of 170-230, elongation at break - 35-50%, and a Poisson’s Ratio of 0.28.

[0073] It is envisaged by the Applicant that the fabric of Figure 3 comprises a FIDPE/Stainless wire ratio of generally 70%/30%. In this aspect, the fabric is envisaged to have a weight of 600gsm. In alternative embodiments, the yarns 316, 318 may be of any other suitable steel, or any other suitable yarn materials may be used instead, such as a metal, or a metal compound, or a metal-polymer composite, or any one of the yarns may be a respective monofilament of high-density polyethylene. In this respect, the yarns 316, 318 may each be made of a different material having different properties, thus giving each yarn 316, 318 a different set of properties. This may be beneficial should a higher level of reinforcement be required in a particular fabric direction.

[0074] The fabric 310 is manufactured on a latch needle warp knitting machine, with four guide bars of the knitting machine being utilised to manufacture the fabric, and each introducing a yarn into the fabric structure. In such an arrangement, the four guide bars may include a front (or first) guide bar 320, a second guide bar 322, a third guide bar 324 and a fourth guide bar 326 that follow the following knitting movements to manufacture the fabric 310:

- front guide bar: 0-1/1 -0//;

- second guide bar: 1 -0/4-5//;

- third guide bar: 0-0/4-4//; (1 in/2 out threading) and

- fourth guide bar: 0-0/0-0/0-0/0-0//1 -1/1 -1/1 -1/1-1// (1 in/2 out threading).

[0075] In use, the front guide bar 320 supplies the yarn for the chain 312 of knitted loops, the second guide bar 322 supplies the weft yarn 314, and the third and fourth guide bars 324, 326 supply the first and second intertwined yarns 316, 318, respectively. [0076] Similar to the guide bar configuration of Figures 1 and 2, the front guide bar 320 carries yarn of chains 312 around the needle hooks (overlap) to produce vertical rows of loops in a configuration known as an open loop pillar stitch. On the successive course, the traverse around the needle hooks is in the opposite direction. There is no underlap movement. The second guide bar 322 carries the weft yarn 314 around the needle hooks (overlap) and then across the back of the needles for several needle spaces during the underlap part of the knitting cycle. It is to be appreciated that the size of these underlaps may be varied to manipulate the weight of the fabric 310 and its horizontal stability. The second guide bar 322 enters and exits between the needles during the overlap part of the knitting cycle, thus being joined to the knitted loops as “laid-in” yarns.

[0077] The third guide bar 324, and the fourth guide bar 326 do not fully thread the intertwined yarns 16, 18 into the fabric 10. Rather, the guide bar operates in a ‘1 in, 2 out’ threading configuration, whereby the following pattern is repeated: one needle insertion is made, then two needle insertions are skipped. In this respect, not all yarn threads 312, 314 are wrapped or threaded by the intertwining yarns 316, 318. In alternative embodiments, the knit pattern of intertwining yarns 316, 318 can be amended to any suitable pattern, for example, 1 in, 1 out, or 1 in and 3 out, or 2 in and 4 out.

[0078] The third guide bar 324 carries yarn 316 and makes alternating underlap and overlap movements across four needle spaces in each cycle, wherein the movements correspond with at least one loop movement of yarn 312.

[0079] The fourth guide bar 326 carries yarn 318 making no underlap movement for one or more knitting cycles as well as no overlaps, and then moves one needle space of underlap before repeating the miss-lap cycle and returning to its original position.

[0080] The yarns 316, 318 introduced by the third and fourth guide bars 324, 326, respectively, interact with knitted loops generated by the first guide bar 320. The configuration of the yarns 316 and 318 of Figure 3 provide the fabric 310 with increased stiffness, low elongation, improved impact resistance and improved load bearing capacity. Careful balancing of the run-ins of the guide bars, 320, 322, 324, 326 optimizes the load bearing capacity of the fabric 310 in both vertical (warp) and horizontal (weft) directions.

[0081] Thus, the front and second guide bars 320, 322 provide the two-dimensional structure of the fabric 310; whereas the third and fourth guide bars 324, 326 supply yarns 316, 318, which respectively, enclose the knitted loops, restricting their ability to deform under load, and providing additional load carrying capacity, stretch resistance, and impact resistance. It is envisaged that the yarns 316, 318 may, instead, be replaced by yarns from a single guide bar.

[0082] The interactions generated by the enclosing of the knitted cells over more than one course by two generally perpendicular yarns 316, 318, running up the chains 12, gives controllable load sharing and movement limitation in the knitted loops, and tightens the grip of the loops on the horizontal laid-in yarns. Balance between these components is achieved by control of run-in to optimize outcomes. The intertwining yarns 316, 318 may provide an enclosure around any number of successive knitted loops of the first guide bar 320, however varying the movements of guide bars 324 and 326, and in particular guide bar 324 will vary the reinforcing properties of the intertwining yarns 316, 318.

[0083] The denier of the yarns of the chain 312, and the weft yarns 314 and the diameter of the intertwining yarns 316, 318 may be selected as desired. As stated previously, the applicant envisages a thickness somewhere between approximately 300 and 1 ,000 denier for the yarns of the chain 312 and weft yarns 314, with a thickness of approximately 400 to 700 denier currently being envisaged by the Applicant as being suitable for use in at least the illustrated Figure 3 embodiment of the invention. The Applicant envisages a diameter of the intertwining yarns 316, 318 somewhere between approximately 0.15mm to 0.25mm. The Applicant has found a denier of 600D for yarns 312 and 314 and a diameter of 0.20m of yarns 316, 318 to be suitable for use in at least the illustrated Figure 3 embodiment of the invention.

[0084] The Applicant has established during trials of the fabric 310 that the fabric stiffness, tear resistance and impact resistance to be improved in comparison to previous embodiments. This is considered by the Applicant to be unique to their invention, at least in the context of solar shade cloth (as well as hail and/or wind protection cloth), and is a result of improved overall strength in the warp and weft direction. The improved stiffness and strength in the warp and weft directions is highly desirable in the context of shade cloth, and in particular load bearing cloth, thus making the cloth more suitable for high impact use in comparison to other embodiments, and thus more versatile than previous embodiments. Moreover, it clearly distinguishes the Applicant’s fabric 310 from their competitor’s products, and their previous products that lack the same load bearing capabilities and warp/weft direction strength. The applicant’s fabric 310 of Figure 3 is not only strong and balanced, it also desirably provides high levels of opacity (and, thus, protection from UV radiation) expected of shade cloth fabrics.

[0085] In the embodiments of Figures 1 , 2 and 3, the applicant observed overall fabric strength of up to 2000 x 2000N/50mm, and overall tear resistance can be up to 400N in either warp or weft direction. The Applicant envisages UV Block to be 90%+. Further, the wire reinforcing yarns are expected to enhance the useful life of the fabric, and it is envisaged the embodiments of Figures 1 to 3 will maintain their properties and structural integrity for approximately 15+ years. Further, the inclusion of metallic reinforcing yarns, in particular a stainless wire, provides inherent electrically conductive properties. These enhanced properties allow the knitted fabric to be more versatile and potentially be used in the construction of impact screening, debris netting, or to act as canopy roofing, or as structural reinforcing of walls, roofs or floors, or safety covers of structures such as rails, bridges or scaffold.

[0086] The use of a conductive metal wire in the knitted fabric also provides safety benefits, in that the fabric may readily dissipate sparks or electrical charges, making the fabric versatile across a plurality of mining operations.

[0087] A reference herein to a patent document or other matter which is given as prior art is not to be taken as an admission that the document or matter was known or that the information it contains was part of the common general knowledge as at the priority date of any of the claims.

[0088] It is to be understood that various alterations, modifications and/or additions may be introduced into the construction and arrangement of the parts previously described without departing from the spirit or ambit of this invention. [0089] Where the terms “comprise”, “comprises”, “comprised” or “comprising” are used in this specification (including the claims) they are to be interpreted as specifying the presence of the stated features, integers, steps or components, but not precluding the presence of one or more other features, integers, steps or components, or group thereto.

[0090] List of Reference Numerals

10 - Fabric 12 - Chains 14 - Weft Yarns 16 - Intertwining yarn 18 - Intertwining yarn 20 - Guide bar 1 22 - Guide bar 2 24 - Guide bar 3 26 - Guide bar 4

110 - Fabric 112 - Chains 114 - Weft yarns 116 - Intertwining yarn 118 - Intertwining yarn 210- Guide bar 1 212- Guide bar 2 214- Guide bar 3 216- Guide bar 4

310 - Fabric 312 - Chains 314 - Weft yarns 316 - Intertwining yarn 318 - Intertwining yarn 320- Guide bar 1 322- Guide bar 2 324- Guide bar 3 326- Guide bar 4