GB2617060A

GB2617060A - Fabric article and method of making the same

Info

Publication number: GB2617060A
Application number: GB2202604.1A
Authority: GB
Inventors: Riaz Naeem
Original assignee: Prevayl Innovations Ltd
Current assignee: Prevayl Innovations Ltd
Priority date: 2022-02-25
Filing date: 2022-02-25
Publication date: 2023-10-04

Abstract

The fabric article is knit using a knitting machine comprising a first and second needle beds. A pocket region comprising a first pocket layer 1712 and a second pocket layer 1714 is knit using half gauge knitting. Prior to knitting the pocket region, a series of racking and transferring of stitches from the first needle bed to the second needle bed, and vice versa is carried out to enable the first and second pocket layers to be formed. A plurality of first pocket layer courses on odd-numbered needles on the first needle bed and a plurality of second pocket layer courses on even-numbered needles on the second needle bed are knitted. A conductive region 1606, 1614 can be knit within the pocket region using a series of knitting steps and conductive yarn.

Description

FABRIC ARTICLE AND METHOD OF MAKING THE SAME

[0001] The present disclosure is directed towards a fabric article and a method of making the same, and in particular is directed towards weft knitted fabric articles and methods of weft knitting particularly for forming fabric articles incorporating electrically conductive yarn. The fabric articles may form wearable articles such as garments.

BACKGROUND

[0002] Fabric articles comprising conductive regions such as in the form of sensing components can be designed to interface with a wearer of the article to determine information such as the wearer's heart rate and rate of respiration. The sensing components may comprise electrodes and connection terminals electrically connected together via an electrically conductive pathway. An electronics module for processing and communication can be removably coupled to the connection terminals so as to receive the measurement signals from the electrodes. The fabric articles may be incorporated into or form a wearable article such as a garment.

[0003] It is desirable to form conductive regions from conductive yarn that is knitted with a base fabric layer (base component) during a single knitting operation. Conductive fabric electrodes are also comfortable to wear and can look, behave and feel like normal garment fabric.

[0004] Knitting conductive yarn is preferred over other techniques, such as weaving, as knitted structures are able to stretch without directly stretching the yarns used to form the knitted structure. Instead, when a knitted structure is stretched, the loops are deformed. This contrasts with woven articles where the yarns are directly stretched when the woven article is stretched. It will be appreciated that stretching a conductive yarn can change its electrical properties.

[0005] United States Patent Application Publication No. 2012/0144561 Al discloses knitting techniques for forming three-dimensional textile electrodes. A conductive surface forming the electrode is knit using a back needle bed of a knitting machine while an isolating surface is knit using the front needle bed. A thread network is provided in a space formed between the conductive surface and the isolating surface using a tucking technique.

[0006] It is desirable to overcome at least some of the problems associated with the prior art, whether explicitly discussed herein or otherwise.

SUMMARY

[0007] According to the present disclosure there is provided a fabric article and method of making the same as set forth in the appended claims. Other features of the invention will be apparent from the dependent claims, and the description which follows.

[0008] According to one aspect of the present invention, there is provided a method of knitting a fabric article using a knitting machine comprising a first needle bed and a second needle bed, the method comprising: knitting, using the first needle bed and the second needle bed, a plurality of courses of non-conductive yarn to form a base layer, the plurality of courses of non-conductive yarn comprising courses of knitted loops; and knitting a pocket region attached to the base layer, the pocket region comprising a first pocket layer and a second pocket layer, the first pocket layer and the second pocket layer being knitted using half gauge knitting.

[0009] This means that the first pocket layer is knit using one of odd or even numbered needles on the first and/or second needle bed and the second pocket layer is knit using the other of the odd and or even needles on the first and/or second needle bed.

[0010] Advantageously, forming a knit pocket in a fabric article in this way allows for needles on both needle beds to knit the individual first and second pocket layers and incorporate other elements such as conductive yarn and filler yarn into the pocket.

[0011] The method may further comprise: prior to knitting the pocket region, racking the second needle bed relative to the first needle bed and transferring stitches on odd-numbered needles from the first needle bed to the second needle bed, and transferring stitches on even-numbered needles from the second needle bed to the first needle bed leaving so as to leave alternate needles on the first needle bed and the second needle bed free; and knitting, using half-gauge knitting, a plurality of first pocket layer courses on odd-numbered needles on the first needle bed and knitting a plurality of second pocket layer courses on even-numbered needles on the second needle bed.

[0012] The method may further comprise knitting a plurality of courses of conductive yarn comprising a series of knitted loops formed on the free needles of the first needle bed.

[0013] The method may further comprise transferring the series of knitted loops formed on the free needles of the first needle bed to needles on the second needle bed to form a first connection region in the pocket region on the second pocket layer.

[0014] The method may comprise the step of knitting at least one course of filler yarn, the at least one course of filler yarn comprising a series of tuck stitches formed on the needles on the second needle bed that are located opposite the needles onto which the knitted loops of the conductive yam are formed.

[0015] A plurality of courses of filler yarn may be knitted and the method may comprise the step of knitting a course non-conductive yarn between courses of filler yarn.

[0016] The method may comprise, prior to knitting the plurality of courses of conductive yarn, knitting at least one course of non-conductive yarn in which loops are formed on the even-numbered needles on the second needle bed and the non-conductive yarn is caught on the free needles on the first needle bed opposing the loops formed on the second needle bed.

[0017] The method may further comprise the step of knitting, using the first needle bed and the second needle bed, a plurality of courses of non-conductive yarn to form a further base layer region after knitting the pocket region, the plurality of courses of non-conductive yarn comprising courses of knitted loops.

[0018] The method may further comprise the step of binding off the first pocket layer after a predetermined number of courses to form a pocket edge.

[0019] Prior to knitting the pocket region, the method may comprise executing a series of racking and transferring steps to transfer all stitches to odd needles on the second needle bed and knitting a plurality of courses of stitches to form a pocket opening; and knitting, using half-gauge knitting, a plurality of first pocket layer courses on odd-numbered needles on the first needle bed and knitting a plurality of second pocket layer courses on even-numbered needles on the second needle bed.

[0020] This enables a pocket region is formed with the pocket opening formed at the beginning of the pcoket region [0021] The plurality of courses of stitches may include a preparatory course of stitches on the first and second needle beds and then at least one course of stitches on every fourth needle on the first needle bed only.

[0022] According to a second aspect of the invention, there is provided a computer program comprising instructions recorded thereon which, when executed by a computer associated with a knitting machine, are operable to cause the computer to control the knitting machine to perform the method as claimed in any preceding claim.

[0023] According to third aspect of the invention, there is provided a knitted fabric article comprising: a base layer comprising first and second knit layers, the base layer comprising a plurality of courses of non-conductive yarn comprising courses of knitted loops; and a pocket region attached to the base layer, the pocket layer comprising a first pocket layer and a second pocket layer, the first pocket layer and the second pocket layer being knitted using half gauge knitting.

[0024] The knitted article may further comprise a plurality of courses of conductive yarn comprising a series of knitted loops to form a connection region in the pocket region on the second pocket layer.

[0025] The knitted article may further comprise at least one course of filler yarn at the connection region, the at least one course of filler yarn comprising a series of tuck stitches formed opposite the knitted loops of the conductive yarn [0026] The knitted article may further comprise a pocket edge for the first pocket layer.

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] To easily identify the discussion of any particular element or act, the most significant digit or digits in a reference number refer to the figure number in which that element is first introduced.

[0028] FIG. 1 is a simplified schematic side-on view of a V-bed knitting machine.

[0029] FIG. 2 is a simplified schematic top-down views of the front and back beds of the knitting machine in FIG. 1.

[0030] FIG. 3 is a simplified schematic top-down views of the front and back beds of the knitting machine in FIG. 1.

[0031] FIG. 4 is a simplified schematic top-down views of the front and back beds of the knitting machine in FIG. 1.

[0032] FIG. 5 is a knitting notation diagram showing a method of knitting loops using the front needle bed of a knitting machine.

[0033] FIG. 6 is a knitting notation diagram showing a method of knitting loops using the back needle bed of a knitting machine [0034] FIG. 7A shows the front face of a fabric article knitted according to the methods shown in FIG. 5 or FIG. 6.

[0035] FIG. 7B shows the back face of a fabric article knitted according to the methods shown in FIG. 5 or FIG. 6.

[0036] FIG. 8 is a knitting notation diagram showing a method of knitting loops using both the front bed and the back bed of a knitting machine.

[0037] FIG. 9 is a knitting notation diagram showing a method of knitting tuck-stitches using the front bed or the back bed of a knitting machine.

[0038] FIG. 10 is a knitting notation diagrams showing a method of knitting tuck-stitches using the front bed or the back bed of a knitting machine.

[0039] FIG. 11 is a knitting notation diagram showing a method of knitting a combination of knitting loops and float stitches and a combination of tuck-stitches and float-stitches using the front and/or back bed of a knitting machine.

[0040] FIG. 12 is a knitting notation diagram showing a method of knitting full-cardigan stitches using a knitting machine.

[0041] FIG. 13 shows a fabric article with full-cardigan stitches.

[0042] FIG. 14 is a knitting notation diagram showing a method of knitting a rib structure using both the front bed and the back bed of a knitting machine using half-gauge knitting.

[0043] FIG. 15 is a knitting notation diagram showing a method of knitting a rib structure using both the front bed and the back bed of a knitting machine after racking the needle beds.

[0044] FIG. 16 illustrates illustrates the knitting operations used to form a fabric article according to aspects of the present disclosure.

[0045] FIG. 17A illustrates the top surface of a fabric article formed using the knitting operations of FIG. 16.

[0046] FIG. 17B illustrates a bottom surface of the fabric article of FIG. 17A.

[0047] FIG. 17C illustrates an aspect of the subject matter in accordance with one embodiment.

[0048] FIG. 18 is a knitting notation diagram showing an example method of knitting a base layer according to aspects of the present disclosure.

[0049] FIG. 19 is a knitting notation diagram showing an example method of knitting a base layer according to aspects of the present disclosure.

[0050] FIG. 20 is a knitting notation diagram showing an example method of knitting a base layer according to aspects of the present disclosure.

[0051] FIG. 21A is a first part of a knitting notation diagram showing an example method of knitting a fabric article comprising an electrode according to aspects of the present disclosure.

[0052] FIG. 21B is a second part of a knitting notation diagram shown in FIG. 21A.

[0053] FIG. 22A shows the bottom surface of a fabric article formed using the knitting operations of FIG. 21A and Fig. 19B [0054] FIG. 22B illustrates the side of the fabric article of Fig. 20A.

[0055] FIG. 22C illustrates the top of the fabric article of Fig. 20A.

[0056] FIG. 23A is a first part knitting notation diagram showing an example method of knitting a base layer with an integral pocket according to aspects of the present disclosure.

[0057] FIG. 23B is a second part of the knitting notation diagram of FIG. 23A.

[0058] FIG. 24A is a first part knitting notation diagram showing an example method of knitting a base layer with an integral pocket according to another aspect of the present disclosure in which a pocket opening is formed prior to forming the pocket layer.

[0059] FIG. 24B is a second part knitting notation diagram showing an example method of knitting a base layer with an integral pocket according to another aspect of the present disclosure in which a pocket opening is formed prior to forming the pocket layer.

DETAILED DESCRIPTION

[0060] The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of various embodiments of the disclosure as defined by the claims and their equivalents. It includes various specific details to assist in that understanding but these are to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the various embodiments described herein can be made without departing from the scope and spirit of the disclosure. In addition, descriptions of well-known functions and constructions may be omitted for clarity and conciseness.

[0061] The terms and words used in the following description and claims are not limited to the bibliographical meanings, but are merely used by the inventor to enable a clear and consistent understanding of the disclosure. Accordingly, it should be apparent to those skilled in the art that the following description of various embodiments of the disclosure is provided for illustration purpose only and not for the purpose of limiting the disclosure as defined by the appended claims and their equivalents.

[0062] It is to be understood that the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0063] The present disclosure relates to fabric articles. The terms fabric and textile are used interchangeably and are not intended to convey different meanings. The fabric articles are knitted from yarns.

[0064] The fabric articles may form or be incorporated into a wearable article. "Wearable article" as referred to throughout the present disclosure may refer to any form of article which may be worn by a user such as a smart watch, necklace, bracelet, or glasses. The wearable article may be a garment. The garment may refer to an item of clothing or apparel. The garment may be a top. The top may be a shirt, t-shirt, blouse, sweater, jacket/coat, or vest. The garment may be a dress, brassiere, shorts, pants, arm or leg sleeve, vest, jacket/coat, glove, armband, underwear, headband, hat/cap, collar, wristband, stocking, sock, or shoe, athletic clothing, personal protective equipment, swimwear, wetsuit or drysuit [0065] The garment may be a tight-fitting garment. Beneficially, a tight-fitting garment helps ensure that the sensor devices of the garment are held in contact with or in the proximity of a skin surface of the wearer. The garment may be a compression garment. The garment may be an athletic garment such as an elastomeric athletic garment.

[0066] The fabric articles may be constructed from natural fibres, synthetic fibres, or a natural fibre blended with one or more other materials which can be natural or synthetic. The yarn may be cotton. The cotton may be blended with polyester and/or viscose and/or polyamide according to the particular application. Silk may also be used as the natural fibre. Cellulose, wool, hemp and jute are also natural fibres that may be used in the wearable article. Polyester, polycotton, nylon and viscose are synthetic fibres that may be used in the wearable article.

[0067] The fabric articles according to the present disclosure comprise knitted fabric. This contrasts with other fabric constructions such as woven fabrics. Woven and knitted fabrics differ in the way yarns are interwoven or knotted together. A woven fabric is created by interweaving pre-tensioned lengths of yarn horizontally in between threads running vertically. These vertical, or warp threads, wrap themselves around the horizontal, or weft thread, after every course, and are themselves pre-tensioned.

[0068] During the manufacture of a woven fabric, all of the yarns running in every direction must be pulled tight at all teams. If the yarns are not tight during knitting, the needles will snag on slacker yarns and break, causing mechanical damage.

[0069] Moreover, woven fabrics incorporating conductive yarn are potentially subjected to a change of resistance when stretched apart because, when stretching a woven fabric, the yarns and thus the conductive particles in the yarn will be stretched further apart. This property is undesirable for sensing operations such as for fabric-based sensing electrodes.

[0070] The present disclosure is directed towards knitted fabrics and, in particular, weft knitted fabrics. Weft knitted fabrics can be knit from a single yarn, but in aspects of the present disclosure multiple yarns are used so as to provide different regions of the fabric with different properties. In weft knitted fabrics, a weft thread is pulled through already formed loops of the same thread and, unlike warp knitting, is not required to be held taut or under stress from a warp thread. This construction allows for stitches (loops) in the fabric article to deform and alter their shape under stress without stretching the yarn itself This helps maintain a constant level of electrical resistance.

[0071] Warp knitted fabrics are another form of knitted article and can be considered a hybrid between woven and knitted. They are formed using loops, but each column of loops is made from its own thread. Warp knitted threads may allow for more stretch than a woven fabric but are generally not as stretchy as weft knitted fabrics.

[0072] To aid in the understanding of the invention, a brief overview of knitting machines and the stitches that knitting machines can generate is provided below in reference to FIG. 1 to FIG. 13. This explanation is not intended to be a full disclosure of the common general knowledge of the skilled person, but instead is only provided to aid in the understanding of the invention.

[0073] FIG. 1 shows a simplified schematic diagram of a conventional V-bed flat knitting machine 102 which is suitable for use in knitting the fabric articles described herein. The present disclosure is not limited to V-bed flat knitting machines and other forms of weft knitting machines may be used.

[0074] The V-bed flat knitting machine 102 comprises a front needle bed 104 and a back needle bed 106. The front needle bed 104 and back needle bed 106 diagonally approach one another at an angle generally between 90 degrees and 104 degrees to each other, giving an inverted V-shape appearance.

[0075] The front needle bed 104 and back needle bed 106 each comprise a large number of needles 108, 110. The needles 108, 110 are typically latch needles. Each needle 108, 110 is able to create and manipulate individual stitches.

[0076] The number of needles per inch is referred to as the gauge of the knitting machine 102. Typically, knitting machines have a gauge of between 7 and 20 However, the gauge can be from 1.5 and, for some knitting machines up to 80 or more.

[0077] The needles 102, 104 are controlled by a needle cam 112 that traverses across the needle beds 104, 106 in both left-to-right and right-to-left directions. The needle cam 112 is designed to knit a course of loops on one or both the front needle bed 104 and the back needle bed 106 during a traverse in either the left or the right direction.

[0078] Yarn is fed to the needle beds 104, 106 by one or more yarn carriers (not shown). Multiple yarn carriers are typically used to allow for a variety of yarns to be introduced into the fabric article at desired locations.

[0079] The needle beds 104, 106 are able to move relative to one another by a process called racking. Racking moves one of the needle beds by one or more needle tricks past the other needle bed, either towards the right or the left. A needle trick is a slot on the needle bed in which a needle moves back and forth. The front and back needle beds 104, 106 are aligned in FIG. 2. In FIG. 3, the back needle bed 106 has been racked to the left relative to the front needle bed 104. In FIG. 4, the back needle bed 106 has been racked to the right relative to the front needle bed 104.

[0080] For most knitting machines, only the back needle bed 106 is able to be racked while the front needle bed 104 stays in a fixed position. However, this is not true for all machines, and front needle beds 104 may also be racked if desired. Racking is not required for knitting, but may be used to create certain effects in the resultant knitted article.

[0081] FIG. 5 shows an example knitting notation diagram in which a plurality of courses of knitted loops are formed using the front needle bed of the knitting machine.

[0082] The diagram comprises several rows of dots where each dot represents a needle on either the front front needle bed or the back needle bed.

[0083] The rows are grouped into pairs (502, 504, 506, 508, 510, 512). In each pair, one row represents needles on the front needle bed and the other row represents needles on the back bed. In each pair, the needles on the front bed are arranged vertically below the needles on the back bed. Each pair of dots show the knitting operations performed to form a knitted course (row of stitches) of the fabric article. A knitted course may also be referred to as a traverse.

[0084] The type of knitting operation performed is represented by the lines that traverse along the dots. Here, the knitting operations are knitted loops as indicated by the lines looping around the dots representing needles on the front bed.

[0085] The diagram is read from bottom to top. This means that the knitting operations represented by pair 502 are performed first followed by 504, 506, 508, 510, 512 in order. Each of the knitting operations 502 -512 involve forming knitted loops using the front needle bed only. The back needle bed is not used. The resultantly formed knitted fabric article comprises six courses of knitted loops where each course comprises three stitches.

[0086] FIG. 6 shows an example knitting notation diagram in which a plurality of courses of knitted loops are formed using the back bed of the knitting machine. Each of the knitting operations 602-612 involve forming knitted loops using back needle bed only. The front needle bed is not used. The resultantly formed knitted fabric article comprises six courses of knitted loops where each course comprises three stitches.

[0087] Reference to "course" or "row" throughout this specification will not be understood as necessarily referring to a full-width course that extends along the full-width of the needle bed or the fabric article unless otherwise specified. Course instead just refers to a row of stitches formed by the knitting machine. Course contrasts with "wales" which refer to columns of vertical stitches formed by the knitting machine.

[0088] FIG. 7A and FIG. 7B show a knitted fabric article 702 that may be formed as a result of front-bed only knitting using the techniques shown in FIG. 5 or back-bed only knitting using the techniques shown in FIG. 6. The knitted fabric article 702 is a single-faced structure as only one of the needle beds is used to form the knitted loops. FIG. 7A shows a front face 704 of the knitted fabric article 702 and FIG. 7B shows a back face 706 of the knitted fabric article 702.

[0089] FIG. 8 shows an example knitting notation diagram in which a plurality of courses of knitting loops are formed using both the front and back needle beds. Each of the knitting operations 802-814 involve forming knitted loops using both the front and the back needle bed. This can be referred as double-knitting. The resultantly formed knitted article comprises a number of courses of knitted loops and has a double-faced structure as compared to the single-faced structure of the fabric article formed using the operations shown in FIG. 5 and FIG. 6.

[0090] FIG. 9 and FIG. 10 show example knitting notation diagram in which a plurality of courses (902-912 and 1002-1014) of tuck stitches are formed using the front needle bed only (FIG. 10) or using the back needle bed only (FIG. 10). Tuck stitches are produced when a needle holding an existing loop also receives a new loop which rather than being intermeshed through the existing loop is tucked in behind the existing loop on the reverse side of the stitch. Tuck stitches are represented in the diagram by as a "V" (or inverted "V") shape that goes around the needle that performs the tuck stitch.

[0091] FIG. 11 is an example knitting notation diagram in which float stitches are interspersed between other needle stitches. Float stitches are produced when a needle misses the yarn which instead floats over to the next chosen needle. Floats are represented in the needle diagram as a bypassed point.

[0092] Knitting operation 1102 involves a series of knitted loops on the front needle bed with float stitches in between. In other words, every other needle on the front needle bed is used to knit a loop.

[0093] Knitting operation 1104 involves a series of knitted loops on the back needle bed with float stitches in between, [0094] Knitting operation 1106 involves a series of tuck stitches on the back needle bed with float stitches in between.

[0095] Knitting operation 1108 involves a series of tuck stitches on the front needle bed with float stitches in between.

[0096] Knitting operation 1110 involves a series of tuck stitches alternatingly performed on the front needle bed and the back needle bed with float stitches in between.

[0097] Tuck-rib stitches are another form of knit structure formed by using knitted loops on one needle bed and tuck-stitches on the other needle bed. Tuck-rib stitches can be used in full-cardigan stitches.

[0098] FIG. 12 is an example knitting notation diagram which shows a series of full-cardigan stitches. Full-cardigan stitches use repeating pairs of knit courses where the second course in each pair uses the reverse of the stitches used for the first course in each pair. The first and second courses both use tuck stitches on one needle bed and knitted loops on the other needle bed.

[0099] The tuck stitches cause the rib wales to gape apart so that the body width spreads outwards. Tuck loops can increase the fabric thickness and make it heavier in weight and bulkier in handle.

[0100] The knitting operation 1202 is a sequence of knitted loops on the front bed and tuck stitches on the back bed. The knitting operation 1204 is the reverse of the sequence of 1202 and has tuck stitches on the front bed and knitted loops on the back bed. Operations 12061212 are a repetition of the sequences 1202 and 1204.

[0101] Some rows may not include tuck stitches.

[0102] FIG. 13 shows a knitted fabric article 1302 formed as a result of the knitting operations of FIG. 12. The full-cardigan stitches result in a balanced 1 x 1 tuck-rib structure with the same appearance when viewed from both faces of the fabric. This drawing is obtained from the textbook: Knitting technology (2001) David J Spencer, Third edition, Woodhead Publishing Limited, Cambridge, UK (Figure 18.6, page 219).

[0103] FIG. 14 shows an example knitting notation diagram in which a plurality of courses 1402, 1404, 1406 of knitting loops are formed using both the front and back needle beds but using alternate needles on each of the front needle bed 104 and back needle bed 106. This is known as half-gauge knitting. In half-gauge knitting there are empty needles between loops.

[0104] FIG. 15 shows an example knitting notation diagram in which a plurality of courses of knitting loops are formed using both the front and back needle beds. In a further step, the back needle bed 106 or the front needle bed 104 are racked as indicated by the double-headed arrow 1510 of FIG. 15.

[01051 In this instance, the needles of each of the back needle bed 106 and the front needle bed 104 are located opposite each other rather than laterally displaced from one another as shown in Figure 8. Each of the knitting operations 1502 to 1508 correspond to knitting operations 802-814 of Figure 8. As with the knitting operations in FIG. 8, the operations involve forming knitted loops using both the front needle bed and the back needle bed.

[0106] FIG. 16 shows an example knitting sequence for forming a fabric article comprising electrodes according to aspects of the present disclosure. Different numbered blocks in the Figure represent different parts of the fabric article formed as a result of the knitting sequence. The knitting operation is performed in one go such that the fabric article is a continuous body of weft knitted fabric. The knitting sequence is read from bottom to top. This means that the part numbered 1602 is knitted first and the part numbered 1622 is knitted last.

101071 The knitting sequence is performed using a knitting machine, such as a V-bed flat knitting machine, comprising a front needle bed and a back needle bed. The knitting involves using different types of yarns held on different yarn carriers of the knitting machine.

[0108] A first part of base layer 1602 is knit using both the front needle bed and the back needle bed. The front needle bed and the back needle bed may be used on different (e.g., alternate courses) or may be used together to form a knit course. The first part of base layer 1602 has a double layer structure as knitted loops are formed on the front needle bed 104 and the back needle bed 106 (although not necessarily simultaneously). The first part of base layer 1602 has a front layer formed by the front needle bed and a back layer formed by the back needle bed. The first part of base layer 1602 is a double-faced structured.

101091 The first part of base layer 1602 comprises a plurality of knit courses. The plurality of knit courses use a first group of needle locations on the knitting machine. The first group of needle locations define the width (in the course direction) of the fabric article. The knit courses may be referred to as full-width courses.

[0110] The first part of base layer 1602 is knitted using non-conductive yarn. Any non-conductive yarn may be used to form the first part of base layer 1602. The yarn may be formed from natural or synthetic fibres or may be blend of natural and synthetic fibres. An example non-conductive yarn is a composite fabric elastomeric yarn. In particular, a composite fabric elastomeric yarn comprising 81% nylon and 19% elastane. Of course other non-conductive yarns may be used as desired by the skilled person.

[0111] Multiple different types of non-conductive yarn may be used in knitting the first part of base layer 1602. The multiple different types of yarns may include yarns with different colours but which may otherwise have the same properties. A combination of different coloured yarns can be used to create pattern effects in the base layer. The multiple different yarns may additionally or separately have different properties.

[0112] Examples of knitting operations used to form the first part of base layer 1602 are described in FIG. 20, FIG. 21A, FIG. 21B, and FIG. 22A -FIG. 22C.

[0113] A pocket region 1604 is knitted using the front needle bed 104 and the back needle bed 106. The pocket region 1604 is formed by knitting a plurality of rows of knitted loops (courses) using both needle beds with a combination of racking and transferring of stitches on alternative needles from the front needle bed to the back needle bed, and vice versa, as will be described in further detail below. The combination of racking and needle transfer forms the pocket region 1604 which comprises a first pocket layer 1712 and a second pocket layer 1714, each pocket layer having a single layer structure and knitted using half-gauge knitting as will be described further below. The pocket region 1604 is knitted using nonconductive yarn and may use the same or one of the same yarns as used to form the first part of base layer 1602.

[0114] As described above with reference to FIG. 15, racking of the front needle bed 104 with respect to the back needle bed 106 moves the needles on each of the needle beds 104, 106 such that they are located directly opposite each other. This enables stitches to be transferred from the front needle bed 104 to the back needle bed 106 and vice versa. In this way, a half gauge knitting structure is created in which the first pocket layer 1712 and the second pocket layer 1714 are formed. This will be described further in relation to FIG. 17C.

[0115] The plurality of rows of knitted loops extend along a partial width of the fabric article and may be referred to as partial courses rather than full-width courses. The pocket region 1604 is knit using a second group of needle locations which is contained within the first group of needle locations used to knit the first part of the base layer. In this example, the second group of needle locations are located in the approximate centre of the first group of needle locations.

[0116] A first part of a first connection region 1606 is knit within the pocket region 1604 using a third group of needle locations contained within the second group of needle locations. The first part of the first connection region 1606 is formed on the second pocket layer 1714 (FIG. 17C) and is covered by the first pocket layer 1712 (FIG. 17B). The first part of the first connection region 1606 forms part of the back layer of the fabric article. The first part of the first connection region 1606 comprises a plurality of rows of knitted loops (courses). The plurality of rows that form the first part of the first connection region 1606 extend along a partial width of the fabric article and may be referred to as partial courses.

[0117] The first part of the first connection region 1606 is knit using electrically conductive yarn. The electrically conductive yarn ("conductive yarn") may be any form of yarn that is electrically conductive. The conductive yarn may be formed from a conductive metal such as copper, silver or stainless-steel. The conductive yarn may comprise a nonconductive or less conductive base yarn which is coated or embedded with conductive material such as carbon, copper or silver. The conductive yarn may be a stainless-steel yarn such as those manufactured by TIBTECH Innovations. The conductive yarn may comprise silver bonded to a nylon core such as the conductive yarn sold as Circuitex (RTM) by Noble Biomaterials Limited.

[0118] In addition to knitting electrically conductive yarn on the back needle bed, a filler yarn is also knitted which helps maintain the shape of the three-dimensional first connection region 1606. An example knitting operation to form the first connection region 1606 is shown in FIG. 23A and FIG. 23B [0119] The first conductive pathways 1608, 1612 is knit using the same electrically conductive yarn as used for the first part of first connection region 1606 and is held on the same yarn carrier. The first part of first conductive pathway 1608 is electrically connected to the first part of first connection region 1606. The first part of first conductive pathway 1608 comprises one or a plurality of rows of knitted loops (courses). The first conductive pathway 1608 is outside of the pocket region 1604 and is knit using a fourth group of needle locations outside of the second group of needle locations and within the group of first needle locations.

[0120] A first electrode 1610 is knit by knitting electrically conductive yarn on the back needle bed. The electrically conductive yarn is the same as used for the first part of first conductive pathway 1608 and is held on the same yarn carrier.

[0121] A plurality of rows of knitted loops (courses) are knitted to using the back needle bed only. The courses of knitted loops are partial length courses that are knitted using a fifth group of needle locations which are contained within the first group of needle locations and are separate from the second group of needle locations and the fourth group of needle locations.

[0122] The second part of first conductive pathway 1612 is knit using the same electrically conductive yarn as used for the first electrode 1610 and is held on the same yarn carrier. The second part of first conductive pathway 1612 is knit in the same way as the first part of the first conductive pathway 1608. The second part of first conductive pathway 1612 is knit using the fourth group of needle locations.

[0123] Knitting a plurality of rows of knitted loops using the back needle bed only causes an excess of material to be formed and held on the back needle bed which enables the first electrode 1610 to adopt a raised three-dimensional profile. In addition to knitting electrically conductive yarn on the back needle bed, non-conductive yarn is also knitted on the front needle bed to form a second part of base layer. The knitted yarn comprises filler yarn which helps pack the space between the conductive yarn and the base layer to help maintain the shape of the three-dimensional first electrode 1610. An example knitting operation to form the first electrode 1610 is shown in FIG. 23A and FIG. 23B.

[0124] A second part of the first connection region 1606 is knit using the same electrically conductive yarn as used for the second part of the first conductive pathway 1612 and is held on the same yarn carrier. The second part of the first connection region 1606 is knit in the same way as the first part of the first connection region 1606.

[0125] First and second parts of a second connection region 1614, first and second parts of a second conductive pathway 1616, 1620 and a second electrode 1618 are all formed as mirror images of the first and second parts of the first connection region 1606, 1614, first and second parts of the first conductive pathway 1608, 1612 and the first electrode 1610.

[0126] The first part of the second connection region 1614 is knit within the pocket region 1604 using a fourth group of needle locations contained within the second group of needle locations. The first part of the second connection region 1614 is formed on the second pocket layer 1714 and is covered by the first pocket layer 1712. The first part of the second connection region 1614 forms part of the back layer of the fabric article. The first part of the second connection region 1614 comprises a plurality of rows of knitted loops (courses). The plurality of rows that form the first part of the second connection region 1614 extend along a partial width of the fabric article and may be referred to as partial courses. The first part of the second connection region 1614 is knit using the back needle bed and is knit using electrically conductive yarn. The electrically conductive yarn is held on a different yarn carrier to the electrically conductive yarn used to knit the first connection region 1606. In this way, the first part of the second connection region 1614 is not electrically connected to the first connection region 1606. The first part of the second connection region 1614 is knit using the same approach as used for the first part of first connection region 1606. The first part of the second connection region 1614 is knit using a sixth group of needle locations contained within the second group of needle locations and separate from the third group of needle locations.

[0127] The second connection region 1614 is knit using electrically conductive yarn. The electrically conductive yarn ("conductive yarn") may be any form of yarn that is electrically conductive. The conductive yarn may be formed from a conductive metal such as copper, silver or stainless-steel. The conductive yarn may comprise a non-conductive or less conductive base yarn which is coated or embedded with conductive material such as carbon, copper or silver. The conductive yarn may be a stainless-steel yarn such as those manufactured by TIBTECH Innovations. The conductive yarn may comprise silver bonded to a nylon core such as the conductive yarn sold as Circuitex (RTM) by Noble Biomaterials Limited [0128] A first part of second conductive pathway 1616 is knit using the same electrically conductive yarn as used for the second connection region 1614 and is held on the same yarn carrier. The first part of second conductive pathway 1616 is knit using the same approach as used for the first part of first conductive pathway 1608. The first part of second conductive pathway 1616 is knit using a seventh group of needle locations contained within the first group of needle locations and separate from the second group of needle locations, fourth group of needle locations, and fifth group of needle locations.

[0129] A second electrode 1618 is knit by knitting electrically conductive yarn on the back needle bed. The electrically conductive yarn is the same as used for the first part of second conductive pathway 1616 and is held on the same yarn carrier. The second electrode 1618 is knit using the same approach as used for the first electrode 1610. The second electrode 1618 is knit using an eighth group of needle locations contained within the first group of needle locations and separate from the second group of needle locations, fourth group of needle locations, fifth group of needle locations, and seventh group of needle locations.

[0130] A second part of second conductive pathway 1620 is knit using the back needle bed. The back needle bed or both the front and back needle bed could also be used. The second part of the second conductive pathway 1620 is knit using the same electrically conductive yarn as used for the second electrode 1618 and is held on the same yarn carrier. The second part of second conductive pathway 1620 is knit using the same approach as used for the second part of first conductive pathway 1612. The second part of second conductive pathway 1620 is knit using the seventh group of needle locations.

[0131] A second part of the second connection region 1614 is knit using the same electrically conductive yarn as used for the second part of the second conductive pathway 1616 and is held on the same yarn carrier. The second part of the second connection region 1614 is knit in the same way as the first part of the second connection region 1614.

[0132] A second part of base layer 1622 is knitted using both the front needle bed and the back needle bed. The second part of base layer 1622 is knit using the same approach as used for the first part of base layer 1602. The second part of base layer 1622 is knit using the first group of needle locations.

[0133] FIG. 17A -FIG. 17C show an example fabric article 1702 formed as a result of the knitting sequence shown in FIG. 16.

[0134] FIG. 17A shows the fabric article 1702 when viewed from the front surface 1706. The fabric article 1702 comprises a base layer 1704, pocket region 1604, a first conductive pathway 1708, and a second conductive pathway 1710.

[0135] The base layer 1704 is formed from the first part of base layer 1602 and second part of base layer 1622 described above in relation to FIG. 16. The base layer 1704 comprises first and second knit layers formed as a result of knitting yarn using both the first needle bed and the second needle bed.

[0136] The first conductive pathway 1708 is formed from the first part of first conductive pathway 1608 and second part of first conductive pathway 1612 described above in relation to FIG. 16.

[0137] The second conductive pathway 1710 is formed from the first part of second conductive pathway 1616 and second part of second conductive pathway 1620 described above in relation to FIG. 16.

[0138] The first conductive pathway 1708 and the second conductive pathway 1710 extend from the internal pocket space 1716 formed by the first pocket layer 1712 and the second pocket layer 1714 of the pocket region 1604 as described above in relation to FIG. 16. The first conductive pathway 1708 is connected to the first connection region 1606 and the second conductive pathway 1710 is connected to the second connection region 1614 within the internal pocket space 1716. The conductive pathways 1710, 1708 extend along the width (course) direction of the fabric article.

[0139] The pocket region 1604 has a pocket opening 1720.

[0140] FIG. 17B shows the fabric article 1702 when viewed from the back surface 1718 of the base layer 1704. The fabric article 1702 comprises the base layer 1704, pocket region 1604, a first electrode first electrode 1610 and a second electrode 1618. The first electrode first electrode 1610 is connected to the first conductive pathway 1708, and the second electrode second electrode 1618 is connected to the second conductive pathway 1710.

101411 The first and second connection regions 1606, 1614 are accessible from within an internal pocket space 1716 formed by the first pocket layer 1712 and the second pocket layer 1714 of the pocket region 1604. The internal pocket space 1716 is accessible through the pocket opening 1720.

[0142] The first connection region 1606 is electrically connected to the first electrode 1610 by the first conductive pathway 1708. The first connection region 1606 and the second connection region 1614 and the first conductive pathway 1708 form a first sensing unit of the fabric article 1702.

[0143] The second connection region 1614 is electrically connected to the second electrode 1618 by the second conductive pathway 1710. The second connection region 1614, the second conductive pathway 1710, and second electrode 1618 form a second sensing unit of the fabric article 1702.

[0144] FIG. 17C shows the fabric article 1702 from above showing how the first connection region first connection region 1606 and the second connection region 1614 are located within the internal pocket space 1716 and are connected to respective first electrodes 1610 by the first conductive pathway 1708 and the second electrode 1618 by the second conductive pathway 1710.

[0145] The pocket opening 1720 of the pocket region 1604 is sized to accommodate an electronics module. The electronics module comprises an interface that couples with the first connection region 1606 and the second connection region 1614 when positioned within the internal pocket space 1716. This brings the electronics module into communication with the first electrode 1610 and the second electrode 1618 and enables the electronics module to received measurement signals from the first electrode 1610 and the the second electrode 1618 and also apply signals to the first electrode 1610 and the second electrode 1618. The electronics module comprises a processor that processes the received measurement signals and a communicator that is able to communicate sensor data to an external device such as a mobile phone. The communicator is typically a wireless communicator such as a Bluetooth (RTM) communicator.

[0146] The first electrode 1610 and the second electrode 1618 may function as sensors for monitoring activity at a body surface of a wearer of the fabric article 1702. The electrodes may be arranged to measure one or more biosignals of a user wearing the fabric article 1702. Here, "biosignal" may refer to any signal in a living being that can be measured and monitored. The electrodes are generally for performing bioelectrical or bioimpedance measurements. Bioelectrical measurements include electrocardiograms (ECG), electrogastrograms (EGG), electroencephalograms (EEG), and electromyography (EMG). Bioimpedance measurements include plethysmography (e.g., for respiration), body composition (e.g., hydration, fat, etc.), and electroimpedance tomography (EIT).

[0147] The first electrode 1610 and the second electrode 1618 may alternatively or additionally function to apply signals to the body surface such as for therapy or treatment applications.

[0148] FIG. 18 shows an example knitting notation diagram for forming the first part of base layer 1602 and/or the second part of base layer 1622 shown in FIG. 16. The knitting notation diagram shows a sequence of steps performed by the knitting machine to form the part of the base layer. Each of the sequence of steps shows knitting operations performed by the front needle bed and the back needle bed of the knitting machine. The knitting notation diagrams are read from bottom to top.

[0149] It will be appreciated that FIG. 18 shows just a simplified example of the knitting operation. The number of courses and the number of stitches per course (the number of needle locations) may vary.

[0150] Steps 1802, 1804, 1806, 1808, 1810, 1812, 1814, 1816 comprise knitting, using the first needle bed and the second needle bed, a plurality of rows (courses) of non-conductive yarn. The plurality of rows of non-conductive yarn comprises rows of knitted loops which are knitted in operations 1802, 1804, 1808, 1810, 1814, 1816. The rows of knitted loops are interspersed with rows comprising tuck stitches which are knitted in operations 1806, 1812. The rows of tuck stitches are sandwiched between pairs of rows of knitted loops. For example, the row of tuck stitches knitted in step 1806 is sandwiched between the rows of knitted loops knitted in steps 1804 and 1808.

[0151] The row of tuck stitches knitted in step 1806 comprises a repeated sequence of tuck stitches. In particular, a sequence of a tuck stitch on the first needle bed followed by a tuck stitch on the second needle bed is repeated along the course.

[0152] The row of tuck stitches knitted in step 1812 comprises the reverse of the sequence used in operation 1806. This means that a sequence of a tuck stitch on the second needle bed followed by a tuck stitch on the first needle bed is repeated along the course.

[0153] Interspersing rows of tuck stitches between tows of knitted loops adds compression to the base layer. This helps urge the first electrode and the second electrode of the fabric article against a skin surface of the wearer when the fabric article is worn. This helps ensure good signal contact between the wearer and the first electrode and the second electrode.

[0154] The rows of knitted loops and the rows of tuck stitches may be knitted using the same yarn held on the same yarn carrier. Alternatively, they may be knitted with different yams held on different yarn carriers.

[0155] FIG. 19 shows an example knitting notation diagram for forming the first part of base layer 1602 and/or the second part of base layer 1622 shown in FIG. 16. The knitting notation diagram shows a sequence of steps performed by the knitting machine to form the part of the base layer. Each of the sequence of steps shows knitting operations performed by the front needle bed and the back needle bed of the knitting machine. The knitting notation diagrams are read from bottom to top.

[0156] Steps 1902, 1904, 1906, 1908, 1910. 1912, 1914, 1916 comprise knitting using the first needle bed and the second needle bed, a plurality of rows (courses) of non-conductive yarn. The plurality of rows of non-conductive yarn comprises rows of knitted loops which are knitted in operations 1902, 1904, 1908, 1910, 1914, 1916. The rows of knitted loops are interspersed with rows comprising tuck stitches which are knitted in operations 1906, 1912. The rows of tuck stitches are sandwiched between pairs of rows of knitted loops. For example, the row of tuck stitches knitted in 1906 is sandwiched between the rows of knitted loops knitted in 1904 and 1908.

[0157] The row of tuck stitches knitted in operation 1906 comprises a repeated sequence of tuck stitches. In particular, a sequence of a tuck stitch on the first needle bed followed by a tuck stitch on the second needle bed is repeated along the course. The tuck stitches are separated by a float stitch.

[0158] The row of tuck stitches knitted in operation 1912 comprises the reverse of the sequence used in operation 1906. This means that a sequence of a tuck stitch on the second needle bed followed by a tuck stitch on the first needle bed is repeated along the course The tuck stitches are separated by a float stitch.

[0159] The row of knitted loops 1902, 1904, 1908, 1910, 1914, 1916 are knitted in a tubular jacquard fashion. The rows are knitted in pairs (1902, 1904), (1908, 1910), (1914, 1916). Each pair comprises a first row 1902, 1908, 1914 knitted using a first yarn held on a first yarn carrier and a second row 1904, 1910, 1916 knitted using a second yarn held on a second yarn carrier. The first yarn and the second yarn may be different types of yarn and may have different colours or other different properties.

[0160] During the knitting of the first rows 1902, 1908, 1914 in the pairs, the first yarn crosses between the first needle bed and the second needle bed at one or more needle locations. This means that knitted loops are selectively formed using both the front needle bed and the second needle bed.

[0161] During the knitting of the second rows 1904, 1910, 1916 in the pairs, the second yarn crosses between the first needle bed and the second needle bed at the same one or more locations. This means that knitted loops are selectively formed using both the front needle bed and the second needle bed.

[0162] Having the first yarn and the second yarn cross between the first and second needle beds introduces colour variations (or other variations in properties) between the front surface and the back surface of the base layer.

[0163] For example, the first yarn may be white, and the second yarn may be black Switching the first yarn and the second yarn between the front and back needle beds enables select parts of the front surface and back surface of the base layer to be black and other parts to be white. It will be appreciated that the back surface will have the inverse of the pattern on the front surface such that black regions on the front surface will be white on the back surface. This is because at needle locations where the first yarn crosses from the front needle bed to the back needle bed, the second yam crosses from the back needle bed to the front needle bed.

[0164] The use of different coloured yarns can be used to produce desired aesthetic effects for the wearable article. In addition, the use of different coloured yarns can be used to form one or more information elements for the wearable article. An information element may provide information about the fabric article. The information could include an owner of the fabric article, a length of the fabric article, a manufacturer of the fabric article or any other form of information as desired by the skilled person. The information element in this example is in the form of text but could equally be an image or a machine-readable code.

[0165] Beneficially, the information element is formed as a result of the knitting of the base layer using the first and second yarns. This means that the information element is integrally formed as part of the knitting process. A separate process such a printing, transferring, or stitching is therefore not required to form the information element. This simplifies the manufacturing process for forming the fabric article.

[0166] FIG. 20 shows an example knitting notation diagram for forming the first part of base layer 1602 and/or the second part of base layer 1622 shown in FIG. 16. The knitting notation diagram shows a sequence of steps performed by the knitting machine to form the part of the base layer. Each of the sequence of steps shows knitting operations performed by the front needle bed and the back needle bed of the knitting machine. The knitting notation diagrams are read from bottom to top.

[0167] Steps 2002, 2004, 2006, 2008, 2010 comprise knitting using the first needle bed and the second needle bed, a plurality of courses of non-conductive yarn. The plurality of courses of non-conductive yarn comprises rows (courses) of knitted loops which are knitted in operations 2002, 2004, 2008, 2010 and which are interspersed with rows comprising tuck stitches which are knitted in operations 2006. The rows of tuck stitches are sandwiched between pairs of rows of knitted loops. For example, the row knitted of tuck stitches knitted in 2006 is sandwiched between the row of knitted loops knitted in 2004 and 2008.

[0168] The row of tuck stitches knitted in operation 2006 comprises a repeated sequence of tuck stitches. In particular, a tuck stitch on the first needle bed and a tuck stitch on the second needle bed are simultaneously knitted. The tuck stitches are separated by a float stitch.

[0169] The rows of knitted loops 2002, 2004, 2008, 2010 are knitted in a tubular jacquard fashion. The rows are knitted in pairs (2002, 2004), (2008, 2010). Each pair comprises a first row 2002, 2008 knitted using a first yarn held on a first yarn carrier and a second row 2004, 2010 knitted using a second yarn held on a second yarn carrier. The first yarn and the second yarn may be different types of yarn and may have different colours or other different properties.

[0170] During the knitting of the first rows 2002, 2008 in the pairs, the first yarn crosses between the first needle bed and the second needle bed at one or more needle locations. This means that knitted loops are selectively formed using both the front needle bed and the second needle bed.

[0171] During the knitting of the second rows 2004, 2010 in the pairs, the second yarn crosses between the first needle bed and the second needle bed at the same one or more locations. This means that knitted loops are selectively formed using both the front needle bed and the second needle bed.

[0172] FIG. 21A and FIG. 21B show an example knitting notation diagram for forming the first electrode 1610 and/or second electrode 1618 shown in FIG. 16. The knitting notation diagram shows a sequence of steps performed by the knitting machine to form the sensor. Each of the sequence of steps shows knitting operations performed by the front needle bed and the back needle bed of the knitting machine. The knitting notation diagrams are read from bottom to top starting at FIG 21A.

[0173] Steps 2102 and 2104 show knitting operations used to form the last two rows of knitted courses of the first part of base layer 1602 (FIG. 16) prior to the knitting of the sensor. The subsequently knitted electrically conductive yarn is attached to the course knitted in 2104. As described above, knitting the first part of base layer 1602 comprises knitting, using the front needle bed and back needle bed, a plurality of courses of nonconductive yarn. The remainder of the first part of base layer 1602 may have the same structure as described in FIG. 18, FIG. 19 or FIG. 20 for example or may have a different knit structure.

[0174] In this example, step 2102 comprises forming knitted loops on the front needle bed and tuck stitches on the back needle bed. Step 2104 comprises forming tuck stitches on the front needle and knitted loops on the back needle bed. The knitting sequence for step 2104 is therefore the reverse of the knitting sequence for step 2102. This means that tuck-rib stitches are knitted in a two-course repeat manner. These alternating sequences of tuck-rib stitches are often referred to as full-cardigan stitches.

[0175] It is not required to knit the first part of the base layer using full-cardigan stitches and other stitches sequences are possible such as half-cardigan stitches, double-knit, interlock, single-knit, links or ribbed. Moreover, the first part of the base layer is not required to only have one type of knit sequence. The majority of the first part of base layer 1602 may be knit using any knit sequence such as those shown in FIG. 18, FIG. 19, and FIG. 20 while the knit courses preceding the conductive yarn may be knit using the full-cardigan stitches shown in this figure.

[0176] Using tuck-rib stitches at least for the knit courses preceding the conductive yarn is advantageous as it enables the base layer to accommodate conductive yarns having a greater thickness.

[0177] The tuck stitches cause the rib wales to gape apart so that the body width spreads outwards to a greater extent than the rib border this results in larger gaps between the stitches. The tuck stitches are not easily visible when viewing the front or back surface of the base layer. This results in the base layer having larger gaps between stitches as compared to other knitting techniques such as just using knitted loops on both needle beds or an interlock knitting technique. These larger gaps enable the base layer to accommodate thicker conductive yarn. Thicker conductive yarn is advantageous as it is less likely to break and is more resistant to washing. Fabric articles with thicker conductive yarn can typically be washed a greater number of times without the measured impedance increasing beyond and acceptable value.

[0178] Yarn thickness may be measured using its yarn count. Yarn count is a measure of the total length per weight of yarn. The yarn count measures include Cotton Count (cc) which gives a measure of the number of 840-yard units in a pound of yarn, Worsted Count (wc) which gives a measure of the number of 560 yard units in a pound of yarn, and Numero Metric Count (nm) which gives a measure of the number of 1000 metre units in a kilogram of yarn.

[0179] Yarn counts are typically represented in the form X/Y, where X is the yarn count for a single ply of yarn and Y is the number of piles that make up the yarn. The number Xis divided by Y to give the final yarn count. In an alternative, yarn counts can also be expressed in the reverse form Y/X. A skilled person would understand the yarn count whichever form is used because of the context.

[0180] For example, a yarn may have a yarn count of 30/2 nm which means that each ply has a yarn count of 30 and that there are two plies that make up the yarn. The final yarn count is 15 nm which means that there are 15000 metres of yarn per kilogram.

[0181] Another yarn may have a yam count of 20/2 nm which means that each ply has a yam count of 20 and that there are two plies that make up the yarn. The final yarn count is 10 nm which means that there are 10000 metres of yarn per kilogram.

[0182] A yarn with a lower yarn count in nm is therefore heavier per unit length and thicker than a yarn with a higher yarn count.

[0183] In some examples, a yarn with a yarn count of 15nm or higher is thin enough that it can fit through the gaps in a base component regardless of the knitting technique used to manufacture the base component, e.g., knit using both needle beds simultaneously or using an interlock technique. However, yarns with yarn counts lower than this value may be more challenging to fit through the gaps between stitches in the base component. This can increase the complexity of the knitting process and reduce the appearance and performance of the resultantly formed fabric article.

[0184] Advantageously, knitting the base layer using cardigan stitches results in larger gaps between the knitted stitches which allows for conductive yarns with a yarn count of less than 15nm to be intermeshed with the base component.

[0185] Moreover, using cardigan stitches result in a base layer with a reduced weight as cardigan stitches use less yarn and are lighter than other knit structures. This enables a wider base layer to be knitted for the same weight/amount of yarn. Moreover, the knitting process for forming a base layer using cardigan stitches is faster than other knitting techniques such as interlock which enables the fabric article 100 to be manufactured more quickly. Therefore, forming the base component using cardigan stitches reduces the time required to knit the fabric article.

[0186] In preferred examples, the courses preceding the conductive yarn are knit using cardigan stitches and the conductive yarn has a yarn count of less than 15nm. The yarn count may be less than 14nm, less than 13nm, less than 12nm, less than 11m. The yarn count may be greater than 5nm, greater than 6nm, greater than 7nm, greater than 8nm, or greater than 9nm. The yarn count may be between 8nm and 12nm and is preferably 10 nm (e.g. a yarn with a yarn count of 20/2 nm). The conductive yarn in this example is preferably a stainless-steel yarn.

[0187] Steps 2106, 2108, 2110 comprise knitting, using the back needle bed, a plurality of courses of electrically conductive yarn to form a first part of a electrode. The plurality of courses of conductive yarn comprise knitted loops. A first of the plurality of courses is connected to the first part of the base layer and a last of the plurality of courses is held on the back needle bed.

[0188] Steps 2112, 2114, 2116, 2118, 2120, 2122, 2124, 2126, 2128, 2130, 2132, 2134, 2136, 2138, 2140, 2142, 2144, 2146 comprise knitting, using the front needle bed, a plurality of courses of non-conductive yarn and a plurality of courses of filler yarn to form the second part of base layer. The courses of filler yarn are interspersed between courses of non-conductive yarn such that each course of filler yarn is provided between two courses of non-conductive yarn.

[0189] The knitting of the plurality of courses of non-conductive yarn is shown in steps 2112, 2114, 2116,2120, 2124, 2128, 2132, 2136, 2140, 2142, 2144, 2146. The knitting of the plurality of courses of filler yarn is shown in steps 2118, 2122, 2126, 2130, 2134, 2138. The course 2118 of filler yarn is provided between courses 2116 and 2120 of nonconductive yarn. The course 2122 of filler yarn is provided between courses 2120 and 2124 of non-conductive yarn. The course 2126 of filler yarn is provided between courses 2124 and 2128 of non-conductive yarn. The course 2130 of filler yarn is provided between courses 2128 and 2132 of non-conductive yarn. The course 2134 of filler yarn is provided between courses 2132 and 2136 of non-conductive yarn. The course 2138 of filler yarn is provided between courses 2136 and 2138. No two courses of filler yarn are provided immediately adjacent one another.

[0190] Each of the courses of filler yarn comprise tuck stitches separated by at least one float stitch. In this example, the tuck stitches are separated by three float stitches. This means that for every tuck stitch there are three float stitches.

[0191] Tuck knitting operations result in the formation of an extra stitch behind an existing stitch. The extra stitch is not visible from the outside surface of the fabric article. The tuck stitch is used to layer-in the filler yarn behind the conductive regions so that it is not visible from the outside of the fabric article.

[0192] Knitting the plurality of courses of conductive yarn on the back needle bed causes the conductive yarn to gather on the back needle bed. As no knitting is performed on the front needle bed at the same time, the knit structure is unbalanced. This is desired as it enables the electrode to adopt a raised three-dimensional profile that extends away from the base layer. To enable the the electrode to maintain its three-dimensional profile, the filler yarn is provided. The filler yarn acts to fill the gap formed between the base layer and the electrode.

[0193] The filler yarn is a thick, bulky, yarn (relative to the non-conductive yarn used for the remainder of the base layer) which can be challenging to knit with consistently on the knitting machine. For example, while a single knitted course of filler yarn could be knitted comprising a tuck stitch at every (or most) needle location, the thickness of the filler yarn could make this difficult to implement as it would be challenging to effectively cram all of this filler yarn into a single previously knitted course of non-conductive yarn. The resultant knit structure could be unstable or the knitting machine may even jam when attempting to knit such an arrangement. To overcome this problem, the filler yarn is knitted in a plurality of courses which are separated by courses of non-conductive yarn. This provides extra material to accommodate filler yarn. Moreover, in each course of filler yarn, float stitches are included to reduce the amount of filler yarn that is knitted in a single course. This means that rather than knitting all of the filler yarn in a single course, the same amount of filler yarn is knitted using multiple courses where each course only introduces a portion of the filler yarn. In this way, the desired effect of providing filler yarn to bulk out the electrode is still achieved but the sensor is easier to knit and more stable.

[0194] The filler yarn in this example is an expanding yarn. The expanding yarn may refer to a yarn that expands under the application of an external stimulus such as heat, pressure or steam. Preferably the yarn expands under the application of steam. The expanding yarn may comprise a polyester material and may be a polyester filament yarn. The expanding yarn used in this example is a Newlife TM polyester filament yarn manufactured by Sinterama S.p.A.

[0195] Beneficially, the use of an expanding yarn means that after the fabric article is constructed, steam (for example) may be applied to cause the yarn to expand and bulk out the shape of the sensor and provide further stability.

[0196] As the expanding yarn expands to fill the space between the sensor and the base layer, the space between the sensor and the base layer does not need to be densely packed with filler material during the knitting operation. Less yarn is required than if a non-expanding filler material were used. For example, a single strand of expanding yarn may provide the necessary support and stability function when the steam (for example) is applied.

[0197] The filler yarn provides a stabilising function for the sensor in order to reduce noise and other electronic artefacts. The filer yarn urges the profile of the sensor out from the base layer and increases the quality, consistency and area of contact for the sensor against the skin surface. This is provided without requiring an increase in the amount of compression applied to the skin surface by the fabric article. Moreover, as the expanding yarn is integrally knit with the remainder of the fabric article, this simplifies the manufacturing process and avoids the need to separately insert filler material after the continuous body of fabric is formed.

[0198] The filler yarn is knit using front needle bed knitting in regions where the conductive yarn is knit using the back needle bed. This is performed so as to anchor the filler yarn on the base layer rather than the sensor. This is particularly desirable when an expanding yarn is used as a filler yarn as it helps ensure that the expanding yarn pushes against and urges the sensor away from the base layer to form the desired three-dimensional shapes.

[0199] In preferred examples, the extra courses of non-conductive yarn knit to accommodate the multiple filler yarn courses also include float stitches as shown in steps 2118, 2122, 2126, 2130, 2134, and 2138. This helps to reduce the total amount of extra nonconductive yarn knit to accommodate the additional courses of filler yarn. Ideally, the number of float stitches per tuck stitch is greater than the number of float stitches per knitted loop.

[0200] The courses of non-conductive yarn and courses of filler yarn can be considered as forming different pairs of courses (2118, 2120), (2122, 2124), (2126, 2128), (2130, 2132), (2134, 2136), (2138, 2140) where each pair comprises a first course of filler yam comprising tuck stitches separated by float stitches and a second course of non-conductive yarn comprising knitted loops separated by float stitches.

[0201] In each pair, the needles used to form the tuck stitches in the first course are also used to form the knitted loops in the second course. In adjacent pairs, different needles are used to form the tuck stitches and knitted loops. For example, in step 2120, odd numbered needles are used to form the knitted loops, while in step 2124, even numbered needles are used to form the knitted loops. Using different needles in different pairs helps spread the filler yarn across the width (course direction) of the electrode.

[0202] As explained above, some of the plurality of courses of non-conductive yarn comprise knitted loops separated by one or more float stitches as shown in steps 2114, 2116, 2120, 2124, 2128, 2132, 2136, 2140, 2142, 2144. The first and last course of nonconductive yarn shown in steps 2112 and 2146 comprise a full sequence of knitted loops without float stitches.

[0203] The filler yarn is not required to be interspersed between every course of nonconductive yarn. In this example, no filler yarn is provided between courses 2112 and 21N, 2114 and 2116, 2140 and 2120, 2142 and 2144 or 2144 and 2146.

[0204] Steps 2148, 2150, 2152, 2154 comprise knitting, using the back needle bed, a plurality of courses of electrically conductive yarn to form a second part of the electrode. The plurality of courses of conductive yarn comprise knitted loops. A first of the plurality of courses is connected to the last of the plurality of courses of the first part of the electrode and a last of the plurality of courses is held on the second needle bed.

[0205] Step 2156 comprises knitting, using the first needle bed and the second needle bed, at least one course of non-conductive yarn to form the third part of the base layer. The third part of base layer is connected to the last of the plurality of courses of the second part of the base layer and the last of the plurality of courses of conductive yarn knit using the second needle bed. In this example, the at least one course of non-conductive yarn comprises a course of tuck stitches on the front needle bed and knitted loops on the back needle bed. The third part of base layer may comprise additional knit courses such as additional full-cardigan stitches and may also comprise additional knit sequences such as those shown in FIG. 18, FIG. 19 and FIG. 20.

[0206] FIG. 22A, FIG. 22B and FIG. 22C show an example fabric article 2202 formed as a result of the knitting operations shown in FIG. 21A and FIG. 21B. The fabric article 2202 may form the first electrode 1610 or the second electrode 1618 of FIG. 16 but is not required to be or be part of the fabric article formed in FIG. 16. The fabric article 2202 may be self-contained or may be incorporated into a different fabric article. For example, the fabric article 2202 may be formed as part of a fabric article comprising a single sensing unit. That is, a single sensor, electrically conductive pathway and connection region provided on a base layer. Multiple sensing units are not required be knit with the fabric article in all examples.

[0207] FIG. 22A shows the fabric article 2202 viewed from below. FIG. 22B shows the fabric article 2202 viewed from the side. FIG. 22C shows the fabric article 2202 viewed from above.

[0208] The fabric article 2202 comprises a base layer 2204 [0209] A first part of base layer 2206 is formed from at least one course of non-conductive yarn. The first part of base layer 2206 is formed as a result of the knitting operations 2102 and 2104 shown in FIG. 21A. As the first part of base layer 2206 is knit using both the front and back needle beds, the first part of base layer 2206 has a double layer construction and comprises first and second fabric layers.

[0210] A second part of base layer 2212 is formed from a plurality of courses of nonconductive yarn interspersed with courses of filler yarn such that each course of filler yarn is provided between two courses of non-conductive yarn. The second part of base layer 2212 is formed as a result of the knitting operations 2112, 2114, 2116, 2118, 2120, 2122, 2124, 2126, 2128, 2130, 2132, 2134, 2136, 2138, 2140, 2142, 2144, 2146 in FIG. 21A and FIG. 21B. The knitted courses are formed using the front needle bed only so that the second part of base layer 2212 only comprises a first fabric layer. The first fabric layer is connected to the first fabric layer of the first part of base layer 2206.

[0211] A third part of base layer 2210 is formed from at least one course of nonconductive yarn. The third part of base layer 2210 is formed as a result of the knitting operation 2156 shown in FIG. 21B. As the third part of base layer 2210 is knit using both the front and back needle beds, the third part of base layer 2210 has a double layer construction and comprises first and second fabric layers. The first fabric layer is connected to the first fabric layer of the second part of base layer 2212.

[0212] The fabric article 2202 further comprises an electrode 2208 formed from a plurality of courses of electrically conductive yarn. The electrode 2208 is formed as a result of the knitting operations 2106, 2108, 2110, 2148, 2150, 2152, 2154 shown in FIG. 21A and FIG. 21B. The electrode 2208 is formed using the back needle bed only so comprises a single fabric layer. This first fabric layer of the electrode 2208 is connected to the second fabric layer of the first part of base layer 2206 and the second fabric layer of the third part of base layer 2210.

[0213] As the second part of base layer 2212 is formed using the front needle bed only it is not visible from the top surface of the fabric article 2202 as shown in FIG. 22A as it is covered by the electrode 2208. The second part of base layer 2212 is visible from the bottom surface of the fabric article 2202 as shown in FIG. 22C.

[0214] As the electrode 2208 is formed using the back needle bed only, it is visible from the bottom surface of the fabric article 2202 as shown in FIG. 22A but is not visible from the top surface as shown in FIG. 22C as it is covered by the second part of base layer 2212. The electrode 2208 forms a raised, three-dimensional region that extends away from a surface of the base layer as shown in FIG. 22B.

[0215] FIG. 23A and FIG. 23B show a sequence of knitting steps used to form an example of pocket region 1604 and the first connection region 1606 of FIG. 16.

[0216] The knitting notation diagram shows a sequence of steps performed by the knitting machine. Each of the sequence of steps shows knitting operations performed by the front needle bed and/or the back needle bed of the knitting machine. The knitting notation diagrams are read from bottom to top starting at FIG. 23A. The knitting diagram shows knitting operations that occur within the second group of needle locations referenced in FIG. 16 which are contained within the first group of needle locations used to form the fabric article of FIG. 16.

[0217] Step 2302 comprises knitting a course of first part of base layer 1602 (FIG. 16) preceding the pocket region 1604 i.e. the final course before the pocket region 1604 is formed. This comprises knitting non-conductive yarn using both the front needle bed and the back needle bed simultaneously to form a double-knit course. As described above, knitting the first part of base layer 1602 comprises knitting, using the front needle bed 104 and back needle bed 106, a plurality of courses of non-conductive yarn. The remainder of the first part of base layer 1602 may have the same structure as described in FIG. 18, FIG. 19 or FIG. 20 for example or may have a different knit structure [0218] Steps 2304 and 2306 shows the knitting operation used to knit the pocket region 1604 which comprises knitting on either the back needle bed 106 or the front needle bed 104. Using a combination of racking (step 2304) and transferring of stitches on alternate needles (step 2306) -from the back needle bed 106 to the front needle bed 104, and vice versa -leaves alternate needles on both the front needle bed 104 and the back needle bed 106 empty. The front needle bed 104 is then used to knit a first pocket layer 1712 on the front needle bed 104 and a second pocket layer 1714 on the back needle bed 106 as will be described in further detail below.

[0219] In step 2304 the back needle bed 106 is racked to the left as shown by the arrow in step 2304. This causes the needles of the front needle bed 104 and the back needle bed 106 to be aligned as is shown in FIG. 15 [0220] After racking, the stitches are then alternatively transferred from the back needle bed 106 to the front needle bed 104 or vice versa as described above. In particular, stitches on the odd-numbered needles of the back needle bed 106 are transferred to the aligned front needle bed 104, whilst on even-numbered needles of the front needle bed 104, the stitch is transferred to the aligned back needle bed 106. In FIG. 23A this is illustrated by the arrows at step 2306.

[0221] This two-step operation enables the first pocket layer 1712 and the second pocket layer 1714 to be knit in a half-gauge knitting operation as loops are only formed on alternate needles of either the front needle bed 104 or the back needle bed 106. Half gauge knitting is discussed in relation to FIG. 14.

[0222] The odd numbered needles on the front needle bed 104 are used to knit the first pocket layer 1712 and the even numbered needles on the back needle bed 106 are used to knit the second pocket layer 1714 -as shown in step 2308 of FIG. 23A.

[0223] Step 2308 comprises knitting the first course for the first pocket layer 1712 and the second pocket layer 1714: the first pocket layer 1712 being knitted using loops on the front needle bed 104 and the second pocket layer 1714 being knitted using stitches on the back needle bed 106. Odd numbered needles are used on the front needle bed 104 and even-numbered needles are used when knitting on the back needle bed 106. Multiple courses using step 2308 are carried out to build up the first pocket layer 1712 and the second pocket layer 1714, so forming the pocket region 1604. Only one pair of courses is shown in FIG. 23A, but the actual number of courses will depend upon the depth of the pocket required.

[0224] At step 2310 the knitting operation prepares for knitting of the first connection region 1606. As mentioned above, the knitting of the pocket region 1604 uses half-gauge knitting and, as such, alternate needles on both needle beds are free. In step 2310, loops are formed on the back needle bed 106 using the even-numbered needles and catching the yarn on the respective empty aligned needle on the front needle bed 104. A number of courses of step 2310 are knit. In the present example, two courses are shown in FIG. 23A.

[0225] At step 2314 the first connection region 1606 is formed on the front needle bed 104. Before starting to build up the first connection region 1606, at step 2312, a layer of loops are formed on the even-numbered needles on the back needle bed 106. To this point, the courses have been knit using non-conductive yarn.

[0226] At step 2314 the first connection region 1606 is formed by knitting a plurality of rows of stitches of electrically conductive yarn on the empty needles of the front needle bed 104 only i.e, the even-numbered needles. The number of courses knitted will depend upon the size of the first connection region 1606 required. In FIG. 23A three courses are shown.

[0227] In step 2316 a course of filler yarn is knit. This is the first of a number of courses of filler yarn. The stitches are formed on the even-numbered needles on the back needle bed 106 and comprise tuck stitches with float stitches between the tuck stitches. The tuck stitch is used to layer-in the filler yarn behind the conductive regions so that it is not visible from the outside of the fabric article. The courses of filler yarn are interspersed with a course of loops of non-conductive yarn at step 2318. The filler yarn in this example is an expanding yarn. The expanding yarn may refer to a yarn that expands under the application of an external stimulus such as heat, pressure or steam. Preferably the yarn expands under the application of steam. The expanding yarn may comprise a polyester material and may be a polyester filament yarn. The expanding yarn used in this example is a Newlife TM polyester filament yarn manufactured by Sinterama S.p.A.

[0228] In FIG. 23B, at step 2320, two courses of filler yarn and interspersed nonconductive yarn are knit, on the back needle bed 106, but the number of courses can be more or less. As described above in relation to FIG. 21A to FIG. 21B, the use of an expanding yarn means that after the fabric article is constructed, steam (for example) may be applied to cause the yarn to expand and bulk out the shape of the first connection region 1606 and provide further stability. Thus, the number of courses knit will depend upon the size of the first connection region 1606 and the required bulking.

[0229] Once all the courses of the filler yarn have been built up, then, at step 2322 further courses of conductive yarn are knit until the first connection region 1606 is finished. When the first connection region 1606 is complete, then, at step 2322, the stitches forming the first connection region 1606 are transferred from the front needle bed 104 to the back needle bed 106. This transfers the stitches forming the first connection region 1606 to form part of the second pocket layer 1714 and restores the arrangement to the half-gauge arrangement with loops on the odd-numbered needles on the front needle bed 104 and on the even-numbered needles on the back needle bed 106 as in step 2308.

[0230] At step 2324 courses of non-conductive yarn are used to continue to knit the rest of the first pocket layer 1712 and second pocket layer 1714 using a plurality of courses of step 2326. Only one course of step 2326 is shown in Figure FIG. 23B, but the actual number will depend upon the required depth of the pocket region 1604.

[0231] The steps for knitting the first connection region 1606 are repeated to form the second connection region 1614.

[0232] When the desired size of pocket region 1604 is reached, the first pocket layer 1712 at the pocket edge of the pocket opening 1720 is finished off by binding off the first pocket layer 1712. Binding off (also known as casting off) is a known technique for finishing of knitting to ensure that the stitches do not unravel.

[0233] Once the pocket region 1604 has been formed, the front needle bed 104 and back needle bed 106 are unracked and stitches picked up on all needles so as to continue knitting the second part of base layer 1622.

[0234] In an alternative embodiment, the pocket region 1604 can be formed with the pocket opening 1720 at the bottom of the pocket region 1604. The pocket opening 1720 is therefore formed before the pcoket pocket region 1604 is formed.

[0235] FIG. 24A and FIG. 24B are knitting diagrams showing how the pocket opening 1720 is formed prior to knitting the first pocket layer 1712 and the second pocket layer 1714 of the pocket region 1604.

[0236] Figure 24A illustrates a number of steps used to prepare the arrangement of the needles on the front needle bed 104 and the back needle bed 106 so that, after a number of steps which include racking of the front needle bed 104 and the back needle bed 106, there exists, in any one pair of adjacent front and back needles (A, B, C, D), adjacent needles (C, D) on the front needle bed 104 which are both empty and only one of a pair of adjacent needles (A,B) on the back needle bed 106 have a stitch thereon with the other also being empty.

[0237] As with previous embodiments,step 2402 comprises knitting a course of first part of base layer 1602 (FIG. 16) preceding the pocket region 1604 i.e. the final course before the pocket region 1604 is formed. This comprises knitting non-conductive yarn using both the front needle bed and the back needle bed simultaneously to form a double-knit course.

As described above, knitting the first part of base layer 1602 comprises knitting, using the front needle bed 104 and back needle bed 106, a plurality of courses of non-conductive yarn. The remainder of the first part of base layer 1602 may have the same structure as described in FIG. 18, FIG. 19 or FIG. 20 for example or may have a different knit structure.

[0238] In step 2404, the back needle bed 106 is racked to the left as shown by the arrow in step 2304. This causes the needles of the front needle bed 104 and the back needle bed 106 to be aligned.

[0239] In step 2406, stitches on the odd-numbered needles on the front needle bed 104 are transferred to the back needle bed 106 i.e., stitches at C transfer to A, leaving needle C empty.

[0240] In step 2408, the back needle bed 106 is racked to the right to return the back needle bed to its initial position.

[0241] In step 2410, the front needle bed 104 is then racked to the left so that needle A is opposite needle D and needle B is opposite needle C. [0242] In step 2412, stitches on needle Don the front needle bed 104 are transferred to the back needle bed 106 so that all the needles on the front needle bed 104 are now empty, with the needles on the back needle beds 106 having stitches on every needle: three on needle A and one on needle B. [0243] In step 2414, the remaining stitch on needle B on the back needle bed 106 is transferred to the opposite empty needle on the front needle bed 104 i.e., transferred to needle C. [0244] At step 2416, the front needle bed 104 is racked to the right and then at step 2418 the back needle bed is racked to the left so that needle C on the front needle bed 104 is opposite needle A on the back needle bed 106. Needle C has a single stitch on it.

[0245] Finally, at step 2420, the remaining stitch on needle C on the front needle bed 104 is transferred to needle A on the back needle bed 106 so that four stitches are on needle A and the other needles B, C, and D are all empty.

[0246] Once all the stitches are on the odd-numbered needle on the back needle bed, then the pocket region 1604 can be knit. Before starting to knit the first pocket layer 1712 and the second pocket layer 1714, a number of courses are knit to form the pocket opening 1720. The knitting diagram for this is shown in FIG. 24B.

[0247] In step 2422 a preparatory course of stitches is formed on the front needle bed 104 and the back needle bed 106 separately, using even needles on the front needle bed 104 and odd needles on the back needle bed 106.

[0248] In step 2424, a first course is knit on the front needle bed 104 in which a stitch is formed on every fourth stitch, starting with an odd-needle, and with float stitches in between.

[0249] In step 2426, a second course is knit on the front needle beds 104 in which a stitch is formed one every fourth stitch on an odd needle, but laterally displaced from the first course so that the stitches are between the stitches of the first course.

[0250] Knitting the first and second course form the edge of a pocket opening 1720 at the start of the formation of the first and second pocket layers.

[0251] After these two courses, forming the first pocket layer 1712 and the second pocket layer 1714 can be formed as described in relation to FIG. 23A.

[0252] The fabric articles described above may be attached to a wearable article such as a chest-strap or other form of garment such as a shirt, t-shirt, tank or bra.

[0253] The fabric articles may be integrally knit with the wearable article. Such as by integrally knitting a garment comprising the fabric article [0254] The present disclosure is not limited to any particular dimension of the electrodes, conductive pathways, or connection regions.

[0255] At least some of the example embodiments described herein may be constructed, partially or wholly, using dedicated special-purpose hardware. Terms such as 'component', 'module' or 'unit' used herein may include, but are not limited to, a hardware device, such as circuitry in the form of discrete or integrated components, a Field Programmable Gate Array (FPGA) or Application Specific Integrated Circuit (ASIC), which performs certain tasks or provides the associated functionality. In some embodiments, the described elements may be configured to reside on a tangible, persistent, addressable storage medium and may be configured to execute on one or more processors. These functional elements may in some embodiments include, by way of example, components, such as software components, object-oriented software components, class components and task components, processes, functions, attributes, procedures, subroutines, segments of program code, drivers, firmware, microcode, circuitry, data, databases, data structures, tables, arrays, and variables. Although the example embodiments have been described with reference to the components, modules and units discussed herein, such functional elements may be combined into fewer elements or separated into additional elements. Various combinations of optional features have been described herein, and it will be appreciated that described features may be combined in any suitable combination. In particular, the features of any one example embodiment may be combined with features of any other embodiment, as appropriate, except where such combinations are mutually exclusive. Throughout this specification, the term "comprising" or "comprises" means including the component(s) specified but not to the exclusion of the presence of others.

[0256] All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

[0257] Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

[0258] The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

CLAIMSI. A method of knitting a fabric article using a knitting machine comprising a first needle bed and a second needle bed, the method comprising: knitting, using the first needle bed and the second needle bed, a plurality of courses of non-conductive yarn to form a base layer, the plurality of courses of non-conductive yarn comprising courses of knitted loops; and knitting a pocket region attached to the base layer, the pocket region comprising a first pocket layer and a second pocket layer, the first pocket layer and the second pocket layer being knitted using half gauge knitting.
2. The method of claim 1, wherein the method further comprises: prior to knitting the pocket region, racking the second needle bed relative to the first needle bed and transferring stitches on odd-numbered needles from the first needle bed to the second needle bed, and transferring stitches on even-numbered needles from the second needle bed to the first needle bed leaving so as to leave alternate needles on the first needle bed and the second needle bed free; and knitting, using half-gauge knitting, a plurality of first pocket layer courses on odd-numbered needles on the first needle bed and knitting a plurality of second pocket layer courses on even-numbered needles on the second needle bed.
3. The method of claim 2, wherein the method further comprises knitting a plurality of courses of conductive yarn comprising a series of knitted loops formed on the free needles of the first needle bed
4. The method of claim 3, wherein the method further comprises transferring the series of knitted loops formed on the free needles of the first needle bed to needles on the second needle bed to form a first connection region in the pocket region on the second pocket layer.
5. The method of claim 3, wherein the method comprises the step of knitting at least one course of filler yarn, the at least one course of filler yarn comprising a series of tuck stitches formed on the needles on the second needle bed that are located opposite the needles onto which the knitted loops of the conductive yarn are formed.
6 The method of claim 5, wherein a plurality of courses of filler yarn are knitted and wherein the method comprises the step of knitting a course non-conductive yarn between courses of filler yarn
7. The method of claim 3, claim 5 or claim 6, wherein the method comprises, prior to knitting the plurality of courses of conductive yarn, knitting at least one course of nonconductive yarn in which loops are formed on the even-numbered needles on the second needle bed and the non-conductive yarn is caught on the free needles on the first needle bed opposing the loops formed on the second needle bed.
8. The method of any preceding claim, wherein the method further comprises the step of knitting, using the first needle bed and the second needle bed, a plurality of courses of nonconductive yarn to form a further base layer region after knitting the pocket region, the plurality of courses of non-conductive yarn comprising courses of knitted loops.
9. The method of any preceding claim, wherein the method further comprises the step of binding off the first pocket layer after a predetermined number of courses to form a pocket edge.
10. The method of claim 1, wherein: prior to knitting the pocket region, executing a series of racking and transferring steps to transfer all stitches to odd needles on the second needle bed and knitting a plurality of course of stitches to form a pocket opening; and knitting, using half-gauge knitting, a plurality of first pocket layer courses on odd-numbered needles on the first needle bed and knitting a plurality of second pocket layer courses on even-numbered needles on the second needle bed.
11. The method of claim 10, where the plurality of course of stitches includes a preparatory course of stitches on the first and second needle beds and then at least one course of stitches on every fourth needle on the first needle bed only.
12. A computer program comprising instructions recorded thereon which, when executed by a computer associated with a knitting machine, are operable to cause the computer to control the knitting machine to perform the method as claimed in any preceding claim.
A knitted fabric article comprising: a base layer comprising first and second knit layers, the base layer comprising a plurality of courses of non-conductive yarn comprising courses of knitted loops; and a pocket region attached to the base layer, the pocket layer comprising a first pocket layer and a second pocket layer, the first pocket layer and the second pocket layer being knitted using half gauge knitting.
14. The knitted fabric article of claim 13 comprising a plurality of courses of conductive yarn comprising a series of knitted loops to form a connection region in the pocket region on the second pocket layer.
15. The knitted fabric article of claim 14 comprising at least one course of filler yarn at the connection region, the at least one course of filler yarn comprising a series of tuck stitches formed opposite the knitted loops of the conductive yarn.