Classifications

• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04B—KNITTING
  • D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
  • D04B1/10—Patterned fabrics or articles
  • D04B1/102—Patterned fabrics or articles with stitch pattern
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04B—KNITTING
  • D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
  • D04B1/10—Patterned fabrics or articles
  • D04B1/12—Patterned fabrics or articles characterised by thread material
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04B—KNITTING
  • D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
  • D04B1/14—Other fabrics or articles characterised primarily by the use of particular thread materials
  • D04B1/18—Other fabrics or articles characterised primarily by the use of particular thread materials elastic threads
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
  • D10B2321/02—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins
  • D10B2321/021—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins polyethylene
  • D10B2321/0211—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins polyethylene high-strength or high-molecular-weight polyethylene, e.g. ultra-high molecular weight polyethylene [UHMWPE]
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2501/00—Wearing apparel
  • D10B2501/02—Underwear
  • D10B2501/021—Hosiery; Panti-hose

Definitions

• the present disclosure relates to knits, and more specifically, to weft knits, methods of making the same, and garments using the same.
• hosiery products such as pantyhose stockings, socks, and tights
• Lycra®, Spandex® often in combination with nylon or polyester.
• these fabrics tend to rip or tear when subjected to frictional forces.
• hosiery products such as sheer hosiery products (e.g. 30 denier and below) made using these fibers are very fragile. They can easily be ripped by hand, foot or hang nail, and are generally considered disposable. Therefore, there remains a need for commercially viable sheer and semi-sheer elastic knits that are not easy to rip.
• embodiments of the present disclosure are directed to knits containing less UHMWPE fibers, methods for their preparation, and garments containing the same.
• Fig. 3 is a photograph of a conventional knit made with LIHMWPE and a stretch fiber, in accordance with some embodiments;
• Fig. 4 is a photograph of a knit having a fine mesh pattern, in accordance with some embodiments;
• the term “denier” used herein refers to a unit of weight indicating the fineness of fiber filaments. It can be measured in mass in grams per 9,000 meters of fiber. A lower denier indicates a finer fiber and a higher denier indicates a thicker or heavier fiber.
• a variation of the breaking work among the plurality of LIHMWPE fibers is less than ⁇ 2.5%, less than ⁇ 3%, less than ⁇ 3.5%, less than ⁇ 4%, less than ⁇ 5%, less than ⁇ 6%, less than ⁇ 7%, less than ⁇ 8%, or less than ⁇ 9%, or less than ⁇ 10%.
• the knit includes a LIHMWPE fiber and a nylon covered Lycra fiber as the stretch fiber. Both the LIHMWPE fiber and the stretch fiber may be textured or flat.
• the nylon has a denier ranging from 1 to 20. In some embodiments, the nylon has a denier ranging from 5 to 20. In some embodiments, the nylon is a multifilament fiber including 5 to 16 filaments.
• the stretch fiber is a nylon covered Lycra fiber formed by covering a monofilament Lycra fiber having a denier ranging from 10 to 40, for example a denier of 17, with a nylon fiber containing 5 to 20 filaments and having a denier ranging from 1 to 20.
• a first feed of the feed machine may run at least one LIHMWPE fiber, which is utilized to knit the first fiber 802 and the third fiber 806 of the knit 800 as shown in Fig. 1 (e.g., the first fiber 802 and the third fiber 806 may be a single, continuous fiber), and a second feed of the feed machine may run at least one stretch fiber, which is utilized to knit the second fiber 804 and the fourth fiber 808 of the knit 800 as shown in Fig. 1 (e.g., the second fiber 804 and the fourth fiber 806 may be a single, continuous fiber).
• the third fiber 806 includes tuck loops 814 and knit loops 816a, 816b as shown in Fig. 1.
• the knit loops 816a, 816b of the third fiber 806 include first knit loops 816a that are smaller than second knit loops 816b.
• the tuck loops 814 of the third fiber 806 and the knit loops 824b of the fourth fiber 808 form respective tuck stitches of the knit 800.
• the respective tuck stitches formed by the tuck loops 814 and the knit loops 824b may hold the knit loops 820b of the second fiber 804.
• the tuck loops 818 of the second fiber 804 and the knit loops 816b of the third fiber 808 form respective tuck stitches of the knit 800.
• the respective tuck stitches formed by the tuck loops 818 and the knit loops 816b may hold the knit loops 812b of the first fiber 802.
• the tuck loops 822 of the fourth fiber 808 and knit loops 826 of the fifth fiber 828 form respective tuck stitches of the knit 800.
• the respective tuck stitches formed by the tuck loops 822 and the knit loops 826 may hold the knit loops 816b of the third fiber 806.
• the second and fourth fibers 804, 808, respectively, have a 1x1 tuck pattern.
• the 1x1 tuck pattern of the second and fourth fibers 804, 808 includes each of the second and fourth fibers 804, 808 having one tuck loop followed by one knit loop and so on, such that the tuck loops and the knit loops switch back and forth one by one along the second and fourth fibers 804, 808.
• the second fiber 804 includes tuck loops 818 and knit loops 820a, 820b as shown in Fig. 1.
• the knit loops 820a, 820b of the second fiber 804 include first knit loops 820a that are smaller than second knit loops 820b.
• the fourth fiber 808 includes tuck loops 822 and knit loops 824a, 824b as shown in Fig. 1.
• the knit loops 824a, 824b of the fourth fiber 808 include first knit loops 824a that are smaller than second knit loops 824b.
• Each one of the tuck loops 814 of the third fiber 806 overlap with a corresponding one of the second knit loops 824b of the fourth fiber 808.
• the tuck loops 814 of the third fiber 806 may physically contact the second knit loops 824b of the fourth fiber 808 such that the tuck loops 814 are at least partially positioned between the fourth fiber 808 and the second fiber 804.
• the tuck loops 814 and the second knit loops 824b wrap around the second fiber 804.
• Each one of the tuck loops 818 of the second fiber 804 overlap with a corresponding one of the second knit loops 816b of the third fiber 806.
• the tuck loops 818 of the second fiber 804 may physically contact the second knit loops 816b of the third fiber 806 such that the tuck loops 818 are at least partially positioned between the third fiber 806 and first fiber 802.
• the tuck loops 818 and the second knit loops 816b wrap around the first fiber 802.
• Each one of the tuck loops 822 of the fourth fiber 808 overlap with a corresponding one of knit loops 826 of a fifth fiber 828, which are represented by dotted lines at the bottom of Fig. 1.
• the tuck loops 822 of the fourth fiber 808 may physically contact the knit loops 826 such that the tuck loops 822 are at least partially positioned between the fifth fiber 828 and the third fiber 806.
• the tuck loops 818 and the knit loops 826 wrap around the third fiber 806.
• the first knit loops 812a of the first fiber 802 wrap around respective fibers (not shown) that would be above the first fiber 802 based on the orientation as shown in Fig. 1.
• the first knit loops 816a of the third fiber 806 wrap around the second fiber 804.
• the first knit loops 820a of the second fiber 804 wrap around the first fiber 802.
• the first knit loops 824a of the fourth fiber 808 wrap around the third fiber 806.
• the knit 800 includes tuck loop regions 832 in which the tuck loops 810, 818, 814, 822 of the first, second, third, and fourth fibers 802, 804, 806, 808 extend. Based on the orientation as shown in Fig. 1 , the tuck loop regions 832 may be columnar (e.g., columnar tuck loop regions) such that the tuck loop regions extend between opposite ends (not shown) of the knit 800.
• Each one of the knit loop regions 830 is adjacent to two of the tuck loop regions 832 such that each of the knit loop regions 830 is separated from other ones of the knit loop regions 830 by the tuck loop regions 832.
• Each one of the tuck loop regions 832 is adjacent to two of the knit loop regions 830 such that each of the tuck loop regions 832 is separated from other ones of the tuck loop regions 832 by the knit loop regions 830.
• the first and third fibers may have some other type of tuck pattern such as a 1x1 tuck pattern, a 5x1 tuck pattern, a 7x1 tuck pattern, a 9x1 tuck pattern, and so forth.
• the tuck pattern of the first and third fibers 802, 806, respectively may be a number of odd tuck patterns such that the odd numbers of the tuck pattern of the first and third fibers 802, 806 formed utilizing the first feed of the feed machine match up with the 1x1 tuck pattern of the second and fourth fibers 804, 808, respectively, formed by the second feed of the feed machine.
• These differing patterns may provide the knit 800 with different patterns such as floral patterns, geometric patterns, floating floral patterns, or some other type of pattern.
• two other options of potential patterns of different embodiments of knits may readily be seen in Figs. 6 (e.g., fine mesh pattern) and 5 (e.g., herringbone pattern).
• the tensile strength of the knit 800 reduces.
• the knit 800 with the first and third fibers 802, 806 having the tuck pattern of 3x1 will be stronger than a knit in which the first and third fibers 802, 806 having a tuck pattern of 5x1 , 7x1, 9x1, and so forth.
• Fig. 1 is a section view of the knit 800
• Fig. 2 is a zoomed-out view of a larger section of the knit 800.
• the knit 800 includes the knit loop regions 830 and the tuck loop regions 832.
• the amount of LIHMWPE material utilized to form the knit 800 as shown in Fig. 1 may be less than 41% of the amount of LIHMWPE material utilized to form the knit as shown in Fig. 3.
• the amount of LIHMWPE material utilized to form the knit 800 as shown in Fig. 1 may be less than 50% of the amount of LIHMWPE material utilized to form the knit as shown in Fig. 3. For example, forming the smaller loop of the knit as shown in Fig. 3 generally will result in the use of a greater amount of LIHMWPE material as compared forming the knit 800 as shown in Fig. 1.
• the knit as shown in Fig. 3 may be relatively stronger and more robust than the knit 800 as shown in Fig. 1 due to the presence of a greater amount of LIHMWPE, the knit 800 is strong enough and robust enough to avoid the ripping and tearing (e.g., shear tearing or ripping) of clothing made of the knit 800 while the clothing is worn.
• the knit loop regions 830 that extend along the knit 800 may provide tensile strength, robustness, and durability greater than the tuck loop regions 832.
• the tuck loop regions 832 allow for the knit 800 to be formed with less UHMWPE material.
• the speed at which the knit 800 as shown in Fig. 1 can be formed may in some embodiments be increased compared to the traditional knit as shown in Fig. 3.
• the knit 800 may be formed relatively quicker than forming the knit as shown in Fig. 3 using a 1-feed knitting machine.
• the reduced amount of LIHMWPE material to form the knit 800 advantageously reduces the cost of manufacturing the knit 800 relative to the traditional knit made with LIHMWPE in every feed as shown in Fig. 3.
• the reduced amount of LIHMWPE material to manufacture the knit 800 reduces the cost of manufacturing the knit 800 as compared to the traditional knit as shown in Fig.
• the knit 800 when used for sheer hosiery or similar garments (e.g., hosiery garments), can be prepared using a mono or multifilament LIHMWPE fiber of 30 denier or below, and a stretch fiber exhibiting elongation above 30% in deniers between 5 and 100, knit together on a 32 gauge or higher knitting machine.
• the knit 800 can be prepared using a mono or multifilament LIHMWPE and a stretch fiber exhibiting elongation above 30%, the combined denier of the knit being between 30 and 220 denier, knit together on 18 gauge or higher knitting machine.
• the costs may be reduced by reducing the amount of LIHMWPE as a 0.5-kilogram (kg) bobbin of LIHMWPE may cost around $250.00 US, whereas, by comparison, a 2.5-kilogram (kg) bobbin of 20 denier single covered/40 denier nylon (20/40/34) fibers costs approximately $600 US.
• the amount of UHMWPE to produce the knit 800 while at the same time using less expensive 20/40/34 fiber the tensile strength of the knit is maintained while keeping costs relatively low as compared to utilizing more UHMWPE.
• the knit 800 may have an aesthetically pleasing look while also being resistant to sheer tearing and ripping, being durable, and being comfortable for an individual to wear.
• knits may have one of the patterns as shown in Fig. 2 (fine rib pattern), Fig. 4 (fine mesh pattern), or Fig. 5 (fine herringbone pattern).
• the knits of the present disclosure may be produced by plating or serving.
• the knits of the present disclosure can be produced by knitting the LIHMWPE fiber and the stretch fiber using a knitting machine.
• the appropriate gauge of the knitting machine is selected according to the end use of the knit, particularly when used in sheer or semi-sheer hosiery that includes pantyhose, leggings, stockings, and socks.
• the gauge number of the knitting machine can affect the stretchability and basis weight of the resulting knit.
• the knit may for example have a gauge ranging from 10 to 40.
• the knit has a gauge ranging from 10 to 15 suitable for producing a knit for socks.
• the knit has a gauge ranging from 28 to 32 suitable for producing a knit for pantyhose or sheer hosiery.
• the knit may have a gauge of at least 32.
• a knitting machine of a single knit type is used.
• the cylinder size of the knitting machine is selected according to the end use of the knit.
• the knitting machine has a cylinder having a size from about 3 inches to about 7 inches suitable for producing knit for making pantyhose.
• the knitting machine has a cylinder having a size from about 5 inches to about 14 inches suitable for producing a knit for socks.
• the knitting machine has a cylinder having a size from about 10 inches to about 14 inches suitable for producing a knit for hosiery.
• the knitting machine has a cylinder having a size from about 10 inches to about 22 inches suitable for producing leggings. In some embodiments, no cylinder is used.
• the fabric of the present disclosure In knitting the fabric of the present disclosure, one can use a conventional knitting machine as a base.
• the knitting machine can have any desired number of feeds, depending on the number needed to cover the number of fiber types being knitted and the speed at which the knitting will occur. Typically knitting machines have 2, 4, or 8 feeds, with the most common being 4 or 8 feeds. In some embodiments, knitting machines can be used with more than 8 feeds. In some embodiments, knitting machines can be used with more than 16 feeds.
• the garment is made using a four-feed hosiery knitting machine. In knitting the hosiery of the present disclosure, each feed can use fibers having deniers ranging from 10 to 50 denier.
• the total denier of the fibers making up the hosiery can be any desired, depending on the weight of hosiery to be produced and the level of sheer desired. In some embodiments, all of the feeds are used. In some embodiments, 5 feeds are used. In some embodiments, the same LIHMWPE fibers with the same properties and the same variations in properties are used on all feeds looping LIHMWPE fibers. In some embodiments, the same LIHMWPE fibers with the same properties and different variations in properties are used on all feeds looping LIHMWPE fibers. In some embodiments different LIHMWPE fibers with different properties and different variations in properties are used on all feeds looping LIHMWPE fibers. In some embodiments different LIHMWPE fibers with different properties and the same variations in properties are used on all feeds looping LIHMWPE fibers.
• the knitting machine can be fitted with tensioners to maintain constant tension on each of the fiber feeds.
• the tension is constant along the length of the individual fiber feed.
• the tension along the length of each of the individual fiber feeds is constant.
• the variation in the tension along the length of the LIHMWPE fiber feed is less than ⁇ 2.5%, less than ⁇ 3%, less than ⁇ 3.5%, less than ⁇ 4%, less than ⁇ 5%, less than ⁇ 6%, less than ⁇ 7%, less than ⁇ 8%, or less than ⁇ 9%, or less than ⁇ 10%.
• the variation in the tension between the different LIHMWPE fiber feeds is less than ⁇ 2.5%, less than ⁇ 3%, less than ⁇ 3.5%, less than ⁇ 4%, less than ⁇ 5%, less than ⁇ 6%, less than ⁇ 7%, less than ⁇ 8%, or less than ⁇ 9%, or less than ⁇ 10%.
• the article of clothing is substantially hydrophobic with a contact angle with water greater than 90 degrees when measured in air.
• the article of clothing can result in an antimicrobial reduction of at least 50% below the same article of clothing comprised of cotton.
• the article of clothing can also reduce the naturally occurring body odors of a person wearing the article of clothing.
• Fig. 6 shows a pair of pantyhose 900 that are formed utilizing the knit of the present disclosure, e.g., knit 800.
• the knit 800 is utilized to form leg portions 902 of the pantyhose 900.
• the leg portions 902 of the pantyhose 900 are stitched or sewn to a waist portion 904 along a seam 906.
• the waist portion 904 may be of a knit having a tighter knitting pattern than the knit 800 utilized to form the leg portions 902 of the pantyhose 900.
• the waist portion 904 may have a knit pattern the same or similar to the traditional knit as shown in Fig. 3.
• the waist portion 904 may be made of an elastic material such that the waist conforms or tightens around a waist of an individual wearing the pantyhose.
• the seam 906 may be a reinforced seam to reduce the likelihood of ripping or tearing along the stitching at the seam coupling the leg portions 902 to the waist portion 904.
• the pantyhose 900 are shown as including the knit 800, it will be readily appreciated that the knit 800 may be utilized to manufacture other types of hosiery garments, underwear, or other like clothing or garments. For example, the knit 800 may be utilized in manufacturing full body hosiery.
• a knit having a fine rib pattern as shown in Fig. 2 is produced using the two- feed knitting technique herein described and further illustrated in Fig. 7.
• the knit is used to make the leg portion of fine rib sheer tights as shown in Fig. 6.
• the knit is formed by knitting a 30 denier LIHMWPE black fiber and a 17 denier Lycra core yarn covered with a single nylon yarn of 13 denier composed of 10 filaments (17sc13/10). Table 1 shows consumption of various fibers in the Fine Rib Sheer tights.
• the consumption of the LIHMWPE fiber in a pair of size small fine rib sheer tights is about 17.20%
• the consumption of the LIHMWPE fiber in a pair of size large fine rib sheer tights is about 17.62%.
• Example 2 Weft Knitting - Fine Mesh Semi-Sheer Tights [00119] A knit having a fine mesh pattern as shown in Fig. 4 is produced using the two-feed knitting technique herein described. The knit is used to make the leg portion of fine mesh semi-sheer tights. The knit is formed by knitting a 30 denier LIHMWPE black fiber and a 20 denier lycra core yarn covered with a single nylon yarn of 40 denier composed of 34 filaments (20sc40/34 s). Table 2 shows consumption of various fibers in the Fine Mesh Semi-Sheer tights.
• a knit having a fine herringbone pattern as shown in Fig. 5 is produced using the two-feed knitting technique herein described.
• the knit is used to make the leg portion of fine herringbone sheer tights.
• the knit is formed by knitting a 30 denier UHMWPE black fiber and a 20 denier lycra core yarn covered with a single nylon yarn of 40 denier composed of 34 filaments (20sc40/34 s).
• Table 3 shows consumption of various fibers in the Fine Herringbone Semi-Sheer tights.
• Example 4 Sheer Tights [00121] A traditional knit having UHMWPE fibers looped in every feed is produced as a comparison. The knit is used to make the leg portion of sheer tights, as shown in Fig. 3. The knit is formed by knitting a 30 denier UHMWPE black fiber and a 17 denier lycra core yarn covered with a single nylon yarn of 13 denier composed of 10 filaments (17sc13/10 s). Table 4 shows consumption of various fibers in the Sheer tights.
• the consumption of the UHMWPE fiber in a pair of size small sheer tights is about 29.60%, and the consumption of the UHMWPE fiber in a pair of size large sheer tights is about 29.87%, both of which are higher than the consumption of the UHMWPE fibers in the pairs of tights formed by knits of the present disclosure, for example as described in Examples 1, 2 and 3.
• the two-feed knitting technique of the present application may thus decrease the usage amount of the LIHMWPE fibers in the tights, which leads to decrease in production costs.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Knitting Of Fabric (AREA)

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• 2022
  • 2022-09-01 EP EP22865573.4A patent/EP4396401A4/de active Pending
  • 2022-09-01 US US18/688,520 patent/US20240352632A1/en not_active Abandoned
  • 2022-09-01 CN CN202280073759.5A patent/CN118369470A/zh active Pending
  • 2022-09-01 WO PCT/US2022/042383 patent/WO2023034529A2/en not_active Ceased

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