US20220047022A1

US20220047022A1 - Garment and Clothes that are Unravel-Free and Roll-Free

Info

Publication number: US20220047022A1
Application number: US17/511,601
Authority: US
Inventors: Eli Almog
Original assignee: Delta Galil Industries Ltd
Current assignee: Delta Galil Industries Ltd
Priority date: 2019-05-08
Filing date: 2021-10-27
Publication date: 2022-02-17
Also published as: IL287664B1; CA3135677A1; IL287664B2; EP3966385A4; EP3966385A1; WO2020225818A1; IL287664A

Abstract

Garment and clothes that are unravel-free and roll-free. A garment includes a particular garment-region made of knitted fabric. A majority of threads of the knitted fabric are yarns other than a thermally-fused thermoplastic yarn, such as polyester, nylon, polypropylene, cellulose, polyurethane. At least one thread of the knitted fabric is a thermally-fused thermoplastic yarn that is knitted integrally in the knitted fabric and is located within N millimeters from an edge or an opening of the garment, wherein N is in the range of 0 to 10 millimeters. The edge or the opening of the garment-region is unravel free and is roll-free, due to inclusion of, or proximity to, the thermally-fused thermoplastic yarn in the knitted fabric.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is a Continuation-in-Part (CIP) of PCT international application number PCT/IL2020/050501, having an international filing date of May 7, 2020, published as international publication number WO 2020/225818 A1, which is hereby incorporated by reference in its entirety; which claims priority and benefit from U.S. 62/844,769, filed on May 8, 2019, which is hereby incorporated by reference in its entirety.

FIELD

Some embodiments are related to the field of clothing.

BACKGROUND

Clothing articles and clothes are typically formed of textile material and are worn on the body. Clothes are worn for various purposes, for example, to keep the human body warm in a cold weather, to protect the human body from rough surfaces or insects or plants, to provide a hygienic barrier between the human body and the environment, to protect the human body from ultraviolet radiation, to cover genitals, for social reasons or as fashion, or the like.

SUMMARY

Some embodiments provide garments and clothes that are Unravel-Free and Roll-Free, as well as systems and methods for producing such garments and clothes.
For example, a garment includes a particular garment-region made of knitted fabric. A majority of threads of the knitted fabric are yarns other than a thermally-fused thermoplastic yarn, such as polyester, nylon, polypropylene, cellulose, polyurethane. At least one thread of the knitted fabric is a thermally-fused thermoplastic yarn that is knitted integrally in the knitted fabric and is located within N millimeters from an edge or an opening of the garment, wherein N is in the range of 0 to 10 millimeters. The edge or the opening of the garment-region is unravel free and is roll-free, due to inclusion of, or proximity to, the thermally-fused thermoplastic yarn in the knitted fabric.
Some embodiments may provide other and/or additional benefits and/or advantages.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of leggings or pants, in accordance with some demonstrative embodiments.

FIG. 2 is a schematic illustration of boxers or short pants or shorts, in accordance with some demonstrative embodiments.

FIG. 3 is a schematic illustration of a shirt, in accordance with some demonstrative embodiments.

FIG. 4 is a schematic illustration of an underwear or panties, in accordance with some demonstrative embodiments.

FIG. 5 is a schematic illustration of a tank-top or a sleeveless shirt, in accordance with some demonstrative embodiments.

FIG. 6 is a schematic illustration of a chest-covering garment, such as bra or brassiere or sports-bra, in accordance with some demonstrative embodiments.

FIGS. 7A-7E are schematic illustrations of various garment-regions, in accordance with some demonstrative embodiments.

FIGS. 8A-8D are schematic illustrations of additional garment-regions, in accordance with some demonstrative embodiments.

FIGS. 9A-9F are schematic illustrations of other additional garment-regions, in accordance with some demonstrative embodiments.

FIGS. 10A and 10B are schematic illustrations of two garment-portions, respectively, in accordance with some demonstrative embodiments.

FIG. 11A is a schematic illustration of a sock, in accordance with some demonstrative embodiments.

FIG. 11B is a schematic illustration of an open-toe sock or a toe-less sock, in accordance with some demonstrative embodiments.

DETAILED DESCRIPTION OF SOME DEMONSTRATIVE EMBODIMENTS

The Applicants have realized that there exists a problem or a challenge in the manufacturing and/or the use of certain garments and clothing article, particularly those formed of Single Jersey fabrics: when such fabric is cut during the garment manufacturing process, the edge or the ending of the garment rolls and/or unravel, either soon after the cut, or after a few days or weeks of use. The Applicants have realized that such fabric tends to roll and/p\or unravel, if it is cut vertically, or at any angle, and especially when it is cut horizontally.
The Applicants have realized that due to these limitations, the cut edges of such fabrics or garment (e.g., waistband, leg hem, neck opening, armhole opening, leg opening, or the like) should be stabilized and secured, by utilizing a suitable technique, such as folding the fabric and then sewing it, or bonding or gluing the edge of the fabric, or adding one or more types of elastics at the edge; or by utilizing a “Seamless” knitting machine which folds the waistband (or the leg hem) via a suitable knitting technique.
The Applicants have realized that these conventional operations (e.g., sewing, bonding, folding, adding elastics, or the like), may in turn cause one or more disadvantages, such as: (1) the garment is losing its clean and smooth hang appeal; (2) the garment feels less comfortable when worn on the human body; (3) the garment appears less flattering when worn on the body; (4) the particular mechanism used (e.g., sewing) may fail over time and may thus cause the problem to re-appear after a few weeks of use; (5) some users do not like the feel and/or the look of a knitted hem or a seam on their body, or do not like the feel and/or the look of a double hem or a folded strip of fabric (e.g., the foot may get stuck into a folded edge of pants when the user performs a wearing operation, and this may cause the folded strip of fabric to un-fold).
The Applicants have developed a system and method for manufacturing clothes and garments, which may be called “cut free” or “free cut”, and which may solve and/or mitigate one or more (or some, or all) of the problems described above, and which may solve and/or mitigate the problems of rolling and/or unraveling of such fabric after it is cut.
Firstly, the methods of the present invention utilize the most appropriate materials or yarns to achieve the desired goal; particularly, the fabric or garment is formed of thermoplastic yarn and/or fusible yarn and/or melting type of yarn(s), which may be knitted by itself to form the garment, or which may be plaited or mixed or combined with other materials or yarns (e.g., Nylon, Polyester, Spandex, Polypropylene, Cotton, Modal, Lycra, or the like). The thermoplastic yarn that is used may be a suitable type of Spandex, or another synthetic yarn, which can be fused or melt in the manufacturing process by using a high-temperature process, such as boarding, or ironing, or curing, or heat press. In some embodiments, improved fusing or melting results are achieved by using a particular Spandex yarn or Spandex-type yarn, such as Lycra, Roica, Creora, or the yarn known as “X4zol™-J Fiber”. Such yarn(s) may comprise, or may be formed of, or may be based on, any suitable fiber or combination of fibers, such as: Polyester based, Polyether based, TPU based, Nylon based, Polypropylene based, or the like.
Secondly, the method of the present invention utilizes a particular knitting technique (or several particular knitting techniques) to achieve the desired goal. In some embodiments, the knitting technique may be Single Jersey knitting. In some embodiments, the knitting technique may be Single Jersey knitting, laid in 1×1, 2×1, 3×1, 4×1, 1×2, 1×3, or the like. In some embodiments, for example, one or more of the following knitting techniques may be used, by itself and/or in combination:
(a) Single Jersey knitting, laid in 1×1, 2×1, 3×1, 4×1, 1×2, 1×3, or the like;
(b) Miss knitting, 1×1, 2×1, 3×1, 4×1, 1×2, 1×3, or the like;
(c) Tack knitting, 1×1, 2×1, 3×1, 4×1, 1×2, 1×3, or the like;
(d) Mesh knitting, 1×1, 2×1, 3×1, 4×1, 1×2, 1×3, or the like;
(e) A combination of two or more different knitting technique to form one garment.
In some embodiments, the laid in Knitting Technique may be used in order to ensure that the special yarn is located close or closer or near the top-panel or top-section of the knitted fabric, such that the special yarn would melt and/or fuse with other yarn(s) once heat processing or pressure-and-heat processing is applied to that area or region.
In some embodiments, in addition to knitting with the special yarn, or instead of it, the special yarn and/or the materials from which the special yarn is formed may be otherwise injected or mixed or rubbed or brushed or applied or inserted or added into the fabric and/or onto the fabric, for example, in the form of paste or gel or liquid or liquid-gel or a suspension (e.g., particles that float or sink within a fluid or a liquid) or emulsion, or as vapor or gas (e.g., which may be sprayed onto or into the fabric) or as drops or droplets, or as a mixture, or as grinded or powdered or fine-grained particles of the special yarn (or its materials) which can otherwise be added to the fabric or the garment; by means of an injector unit, an applicator, a brush, a spraying unit, a brushing unit, a disposing unit, a three-dimensional printing unit, a printer, a nozzle that injects or spits out liquid or gel or paste or liquid-gel or other material, an extruder unit, or the like; which may operate in accordance with a control unit or regulator unit that controls the movement and/or direction and/or amount of material(s) that are injected or added to the fabric as well as their pattern of disposition. Optionally, the inserted or printed or injected material(s) may be subject to a curing process, such as by causing a wait or a delay in the manufacturing process to enable such material(s) to cure and/or to solidify, or by exposing such materials (after applying them to the fabric) to a particular level of heat and/or ultra-violet (UV) light and/or other types of illumination or other curing process.
Thirdly, the method of the present invention utilizes a particular thermal process to achieve the desired goal. During the manufacturing process, the garment being produced is heat-processed, for example, before dyeing and/or after dyeing. The heat-based processing may include, for example, heat press, ironing, boarding, heat and pressure treatment, or the like; at an appropriate temperature (e.g., in the range of 80 to 250 degrees Celsius); and by applying a particular level of pressure; and for a pre-defined period of time.
Fourthly, the garment being produced (or its fabric) is cut, and particularly its edges or ends are cut (e.g., armholes, leg opening, leg hems, waistbands, or the like), via a suitable cutting technique or cutting equipment such as: scissors, knife, blade, guillotine, ultra-sonic cutting (e.g., cutting while also applying ultra-sonic vibrations exactly at the time of cutting), laser cut, over lock cutting machine, or the like.
Reference is made to FIGS. 1-6, which demonstrate some garments having “cut free” lines or edges or zones or regions that are marked with two letters (“AA”, “BB”, “CC”, and so forth), in accordance with some demonstrative embodiments of the present invention.
The relevant lines or regions or edges (e.g., having or comprising, or formed of, the melting TPU yarn or fiber, or the X4zol™-J Fiber, or the X4zol™ yarn or thread, or a Spandex or Spandex-type yarn or thread, or a fiber or yarn made of X4zol™, or other “Special Yarn” as detailed herein), may be horizontal, or vertical, or slanted/diagonal, or may be wave shaped or zigzag shaped, or may be round or curved, or may be cut or formed in accordance with a particular pre-defined pattern or shape.
The garments may be, for example, underwear, shape-wear, sport wear, active wear, sleep wear, swim wear, out wear, lingerie, and any other suitable clothing article, for use indoors and/or outdoors, which may be worn immediately on the skin of the human body (e.g., underwear, T-shirt, leggings) or may be worn on top of another layer of clothing (e.g., jacket, long-sleeve shirt, pajama).
The cutting line may have different thickness and/or width of the knitting lines, which after cutting may disappear or may not be visible to the end-user; or alternatively, may still remain and be visible (e.g., such as in zone EE). In some embodiments, utilization of the X4zol™-J Fiber as the Special Yarn, may lead to improved results of unravel-free and/or roll-free edge of the garment or fabric. In some embodiments, utilization of an X4zol™ yarn as the Special Yarn, may lead to improved results of unravel-free/roll-free edge of the garment or fabric. In some embodiments, utilization of a Spandex yarn as the Special Yarn, may lead to improved results of unravel-free/roll-free edge of the garment or fabric. In some embodiments, utilization of a Lycra yarn as the Special Yarn, may lead to improved results of unravel-free/roll-free edge of the garment or fabric. Various implementations may selectively utilize one particular type of fiber or yarn as the Special Yarn, in order to achieve the best results for a particular type of garment (e.g., shirt, underwear, leggings) and/or for a particular garment-region (e.g., arm-hole, leg-opening, waist-band) and/or in combination with one or more Other Yarn(s) (e.g., cotton, polyester, wool, or the like).
In some embodiments, the Special Yarn is knitted by itself, exclusively as a single yarn, in a particular region or area of the garment; such that a particular garment-region is formed exclusively of that Special Yarn and not of any Other Yarn(s); and that garment-region then undergoes heat processing (or simultaneous pressure-and-heat processing) which melts and/or fuses the Special Yarn and provides the non-unraveling/non-rolling effect. In other embodiments, the Special Yarn is knitted together with one additional Other Yarn, in a particular region or area of the garment; such that a particular garment-region is formed exclusively of that Special Yarn plus one additional Other Yarn; and that garment-region then undergoes heat processing (or simultaneous pressure-and-heat processing) which melts and/or fuses the Special Yarn and provides the non-unraveling/non-rolling effect. In other embodiments, the Special Yarn is knitted together with two-or-more additional Other Yarns (which may be of a single type of Other Yarn, or which may be of two or more types of Other Yarn), in a particular region or area of the garment; such that a particular garment-region is formed exclusively of that Special Yarn plus two-or-more additional Other Yarns; and that garment-region then undergoes heat processing (or simultaneous pressure-and-heat processing) which melts and/or fuses the Special Yarn and provides the non-unraveling/non-rolling effect.
In other embodiments, the Special Yarn is knitted as a Feeder Yarn of one, or two, or N yarns of a multi-yarn or multi-thread knitting machine or seamless knitting machine (e.g., 1 or 2 or N out of 8 yarns or out of 8 knitting needles), in a particular region or area of the garment; such that a particular garment-region is formed of that Special Yarn plus additional Other Yarn(s); and that garment-region then undergoes heat processing (or simultaneous pressure-and-heat processing) which melts and/or fuses the Special Yarn and provides the non-unraveling/non-rolling effect.
FIG. 1 is a schematic illustration of leggings 101 or pants, in accordance with some demonstrative embodiments of the present invention. The lines that are shown in thicker ink, indicate the unravel free/roll-free edges or openings or garment-regions.
FIG. 2 is a schematic illustration of boxers 102 or short pants or shorts, in accordance with some demonstrative embodiments of the present invention. The lines that are shown in thicker ink, indicate the unravel free/roll-free edges or openings or garment-regions.
In FIG. 1 and FIG. 2, reference sign “CC” indicates clean-cut edges or zones or unravel-free or roll-free zones or garment-portions or garment-regions, located at or near the waist band. The Special Yarn may be knitted or fused or otherwise placed in or at or near the garment-region marked with “CC”, or in or at or near the waist-band, or within N millimeters of the edge thereof (e.g., wherein N is, for example, 0 or 1 or 2 or 3 or 4 or 5 or 7 or 10 millimeters; or, wherein N is a number in the range of 0 to 5 millimeters; or, wherein N is a number in the range of 0 to 10 millimeters; or the like), or near or at the edge of the garment near that reference sign; and such Special Yarn is fused or melted or heat-pressed or heat-treated or pressure-and-heat treated, in order to achieve and/or improve the unravel-free/roll-free characteristic of that garment-region.
In FIG. 1 and FIG. 2, Reference signs “DD” indicate clean-cut edges or zones or unravel-free or roll-free zones or garment-portions or garment-regions, located at or near the leg hems. The Special Yarn may be knitted or fused or otherwise placed in or at or near the garment-region marked with “DD”, or in or at or near the leg hem, or within N millimeters of the edge thereof (e.g., wherein N is, for example, 0 or 1 or 2 or 3 or 4 or 5 or 7 or 10 millimeters; or, wherein N is a number in the range of 0 to 5 millimeters; or, wherein N is a number in the range of 0 to 10 millimeters; or the like), or near or at the edge of the garment near that reference sign; and such Special Yarn is fused or melted or heat-pressed or heat-treated or pressure-and-heat treated, in order to achieve and/or improve the unravel-free/roll-free characteristic of that garment-region.
FIG. 3 is a schematic illustration of a shirt 103, in accordance with some demonstrative embodiments of the present invention. For demonstrative purposes, a short-sleeve shirt is shown; yet similar features may be used in a long-sleeve shirt or a semi-long sleeve shirt. The lines that are shown in thicker ink, indicate the unravel free/roll-free edges or openings or garment-regions.
In FIG. 3, reference signs “AA” indicate clean-cut edges or zones or unravel-free or roll-free zones or garment-portions or garment-regions, located at or near sleeve ends. The Special Yarn may be knitted or fused or otherwise placed in or at or near the garment-region marked with “AA”, or in or at or near the sleeve ends, or within N millimeters of the edge thereof (e.g., wherein N is, for example, 0 or 1 or 2 or 3 or 4 or 5 or 7 or 10 millimeters; or, wherein N is a number in the range of 0 to 5 millimeters; or, wherein N is a number in the range of 0 to 10 millimeters; or the like), or near or at the edge of the garment near that reference sign; and such Special Yarn is fused or melted or heat-pressed or heat-treated or pressure-and-heat treated, in order to achieve and/or improve the unravel-free/roll-free characteristic of that garment-region.
In FIG. 3, reference sign “HH” indicates clean-cut edges or zones or unravel-free or roll-free zones or garment-portions or garment-regions, located at or near the neck line. The Special Yarn may be knitted or fused or otherwise placed in or at or near the garment-region marked with “HH”, or in or at or near the neck line, or within N millimeters of the edge thereof (e.g., wherein N is, for example, 0 or 1 or 2 or 3 or 4 or 5 or 7 or 10 millimeters; or, wherein N is a number in the range of 0 to 5 millimeters; or, wherein N is a number in the range of 0 to 10 millimeters; or the like), or near or at the edge of the garment near that reference sign; and such Special Yarn is fused or melted or heat-pressed or heat-treated or pressure-and-heat treated, in order to achieve and/or improve the unravel-free/roll-free characteristic of that garment-region.
In FIG. 3, reference sign “BB” indicates clean-cut edges or zones or unravel-free or roll-free zones or garment-portions or garment-regions, located at or near the hem area or the tail area. The Special Yarn may be knitted or fused or otherwise placed in or at or near the garment-region marked with “BB”, or in or at or near the hem area or tail area, or within N millimeters of the edge thereof (e.g., wherein N is, for example, 0 or 1 or 2 or 3 or 4 or 5 or 7 or 10 millimeters; or, wherein N is a number in the range of 0 to 5 millimeters; or, wherein N is a number in the range of 0 to 10 millimeters; or the like), or near or at the edge of the garment near that reference sign; and such Special Yarn is fused or melted or heat-pressed or heat-treated or pressure-and-heat treated, in order to achieve and/or improve the unravel-free/roll-free characteristic of that garment-region.
FIG. 4 is a schematic illustration of an underwear 104 or panties, in accordance with some demonstrative embodiments of the present invention. The lines that are shown in thicker ink, indicate the unravel free/roll-free edges or openings or garment-regions.
In FIG. 4, reference sign “EE” indicate clean-cut edges or zones or unravel-free or roll-free zones or garment-portions or garment-regions, located at or near the waist band. The Special Yarn may be knitted or fused or otherwise placed in or at or near the garment-region marked with “EE”, or in or at or near the waist band, or within N millimeters of the edge thereof (e.g., wherein N is, for example, 0 or 1 or 2 or 3 or 4 or 5 or 7 or 10 millimeters; or, wherein N is a number in the range of 0 to 5 millimeters; or, wherein N is a number in the range of 0 to 10 millimeters; or the like), or near or at the edge of the garment near that reference sign; and such Special Yarn is fused or melted or heat-pressed or heat-treated or pressure-and-heat treated, in order to achieve and/or improve the unravel-free/roll-free characteristic of that garment-region.
In FIG. 4, reference sign “FF” indicate clean-cut edges or zones or unravel-free or roll-free zones or garment-portions or garment-regions, located at or near the leg openings. The Special Yarn may be knitted or fused or otherwise placed in or at or near the garment-region marked with “FF”, or in or at or near the leg opening, or within N millimeters of the edge thereof (e.g., wherein N is, for example, 0 or 1 or 2 or 3 or 4 or 5 or 7 or 10 millimeters; or, wherein N is a number in the range of 0 to 5 millimeters; or, wherein N is a number in the range of 0 to 10 millimeters; or the like), or near or at the edge of the garment near that reference sign; and such Special Yarn is fused or melted or heat-pressed or heat-treated or pressure-and-heat treated, in order to achieve and/or improve the unravel-free/roll-free characteristic of that garment-region.
FIG. 5 is a schematic illustration of a tank-top 105 or a sleeveless shirt, in accordance with some demonstrative embodiments of the present invention. The lines that are shown in thicker ink, indicate the unravel free/roll-free edges or openings or garment-regions.
In FIG. 5, reference sign “HH” indicates clean-cut edges or zones or unravel-free or roll-free zones or garment-portions or garment-regions, located at or near the neck line. The Special Yarn may be knitted or fused or otherwise placed in or at or near the garment-region marked with “HH”, or in or at or near the neck line, or within N millimeters of the edge thereof (e.g., wherein N is, for example, 0 or 1 or 2 or 3 or 4 or 5 or 7 or 10 millimeters; or, wherein N is a number in the range of 0 to 5 millimeters; or, wherein N is a number in the range of 0 to 10 millimeters; or the like), or near or at the edge of the garment near that reference sign; and such Special Yarn is fused or melted or heat-pressed or heat-treated or pressure-and-heat treated, in order to achieve and/or improve the unravel-free/roll-free characteristic of that garment-region.
In FIG. 5, reference signs “JJ” indicate clean-cut edges or zones or unravel-free or roll-free zones or garment-portions or garment-regions, located at or near the arm openings or the arm holes. The Special Yarn may be knitted or fused or otherwise placed in or at or near the garment-region marked with “JJ”, or in or at or near the arm hole or arm opening, or within N millimeters of the edge thereof (e.g., wherein N is, for example, 0 or 1 or 2 or 3 or 4 or 5 or 7 or 10 millimeters; or, wherein N is a number in the range of 0 to 5 millimeters; or, wherein N is a number in the range of 0 to 10 millimeters; or the like), or near or at the edge of the garment near that reference sign; and such Special Yarn is fused or melted or heat-pressed or heat-treated or pressure-and-heat treated, in order to achieve and/or improve the unravel-free/roll-free characteristic of that garment-region.
In FIG. 5, reference sign “BB” indicates clean-cut edges or zones or unravel-free or roll-free zones or garment-portions or garment-regions, located at or near the hem area or the tail area. The Special Yarn may be knitted or fused or otherwise placed in or at or near the garment-region marked with “BB”, or in or at or near the hem area or tail area, or within N millimeters of the edge thereof (e.g., wherein N is, for example, 0 or 1 or 2 or 3 or 4 or 5 or 7 or 10 millimeters; or, wherein N is a number in the range of 0 to 5 millimeters; or, wherein N is a number in the range of 0 to 10 millimeters; or the like), or near or at the edge of the garment near that reference sign; and such Special Yarn is fused or melted or heat-pressed or heat-treated or pressure-and-heat treated, in order to achieve and/or improve the unravel-free/roll-free characteristic of that garment-region.
FIG. 6 is a schematic illustration of a chest-covering garment 106, such as bra or brassiere or sports-bra, in accordance with some demonstrative embodiments of the present invention. The lines that are shown in thicker ink, indicate the unravel free/roll-free edges or openings or garment-regions.
In FIG. 6, reference sign “HH” indicates clean-cut edges or zones or unravel-free or roll-free zones or garment-portions or garment-regions, located at or near the neck line. The Special Yarn may be knitted or fused or otherwise placed in or at or near the garment-region marked with “HH”, or in or at or near the neck line, or within N millimeters of the edge thereof (e.g., wherein N is, for example, 0 or 1 or 2 or 3 or 4 or 5 or 7 or 10 millimeters; or, wherein N is a number in the range of 0 to 5 millimeters; or, wherein N is a number in the range of 0 to 10 millimeters; or the like), or near or at the edge of the garment near that reference sign; and such Special Yarn is fused or melted or heat-pressed or heat-treated or pressure-and-heat treated, in order to achieve and/or improve the unravel-free/roll-free characteristic of that garment-region.
In FIG. 6, reference signs “JJ” indicate clean-cut edges or zones or unravel-free or roll-free zones or garment-portions or garment-regions, located at or near the arm openings or the arm holes. The Special Yarn may be knitted or fused or otherwise placed in or at or near the garment-region marked with “JJ”, or in or at or near the arm hole or arm opening, or within N millimeters of the edge thereof (e.g., wherein N is, for example, 0 or 1 or 2 or 3 or 4 or 5 or 7 or 10 millimeters; or, wherein N is a number in the range of 0 to 5 millimeters; or, wherein N is a number in the range of 0 to 10 millimeters; or the like), or near or at the edge of the garment near that reference sign; and such Special Yarn is fused or melted or heat-pressed or heat-treated or pressure-and-heat treated, in order to achieve and/or improve the unravel-free/roll-free characteristic of that garment-region.
In FIG. 6, reference sign “GG” indicates clean-cut edges or zones or unravel-free or roll-free zones or garment-portions or garment-regions, located at or near the lower band. The Special Yarn may be knitted or fused or otherwise placed in or at or near the garment-region marked with “GG”, or in or at or near the lower band area, or within N millimeters of the edge thereof (e.g., wherein N is, for example, 0 or 1 or 2 or 3 or 4 or 5 or 7 or 10 millimeters; or, wherein N is a number in the range of 0 to 5 millimeters; or, wherein N is a number in the range of 0 to 10 millimeters; or the like), or near or at the edge of the garment near that reference sign; and such Special Yarn is fused or melted or heat-pressed or heat-treated or pressure-and-heat treated, in order to achieve and/or improve the unravel-free/roll-free characteristic of that garment-region.
In some embodiments, the Cut Free edges or zones or regions may serve or may achieve one or more goals, for example: (a) avoiding or preventing or reducing or mitigating the Unraveling of the fabric edge or the garment edge; (b) avoiding or preventing or reducing or mitigating the Rolling (e.g., inward rolling; outward rolling; slanted rolling) of the fabric edge or the garment edge; (c) avoiding or preventing or reducing or mitigating the Folding (e.g., inward folding; outward folding; slanted folding) of the fabric edge or the garment edge; (d) assisting the fabric edge and/or the garment edge to Cling to the human body or human skin, and/or preventing or reducing movement or “sliding” or rolling of the garment edge (or fabric edge) relative to the body of the human wearer, particularly for seam-less fabrics.
Reference is made to FIGS. 7A-7E, FIGS. 8A-8D, and FIGS. 9A-9F, which are schematic illustrations of various garment-regions 701-715, in accordance with some demonstrative embodiments of the present invention. Each one of garment-regions 701-715 may be, for example, a region that is close to or in proximity to garment edge or a garment opening (e.g., being within N millimeters of the garment edge or the garment opening; wherein N is, for example, 0 or 1 or 2 or 3 or 4 or 5 or 7 or 10 millimeters; or, wherein N is a number in the range of 0 to 5 millimeters; or, wherein N is a number in the range of 0 to 10 millimeters; or the like), or may include an ending or an edge or an opening of the garment; such as, being a lower end of leggings or pants, or being an ending region of a short sleeve or a long sleeve, or being a region that ends with an arm opening or a leg opening or a foot opening or a neck opening, or the like. The marking “SY” denotes a Special Yarn; and the marking “OY” denotes Other Yarn (namely, another type of yarn that is not the Special Yarn).
In garment-region 701, the Special Yarn is a single yarn knitted at (or near) the edge or the ending of the garment-region; or is a set or a batch of such threads of Special Yarns that are knitted together at the same direction (e.g., generally parallel to each other, forming a thicker yarn), at (or near) the edge or the ending of the garment-region; whereas the remainder of the garment-region is formed of Other Yarn and does not comprise the Special Yarn. The area having the Special Yarn undergoes heat processing or heat pressing, such that the Special Yarn melts and fuses with its surrounding, and results in a non-folding/non-raveling/non-rolling edge line or edge-zone of the garment-region.
In garment-region 702, the Special Yarn is a set of generally-parallel yet spaced-apart Special Yarns (e.g., with at least one thread of Other Yarn between each two neighboring Special Yarn threads), that are generally parallel to the actual edge of the garment-region, located at (or near) the edge or the ending of the garment-region; whereas the remainder of the garment-region is formed of Other Yarn and does not comprise the Special Yarn. The area having the Special Yarn undergoes heat processing or heat pressing, such that the Special Yarn melts and fuses with its surrounding, and results in a non-folding/non-raveling/non-rolling edge line or edge-zone of the garment-region.
In garment-region 715, the Special Yarn is a set of generally-parallel yet spaced-apart Special Yarns (e.g., with at least one thread of Other Yarn between each two neighboring Special Yarn threads), that are generally perpendicular to the actual edge of the garment region, located at (or near) the edge or the ending of the garment-region; whereas the remainder of the garment-region is formed of Other Yarn and does not comprise the Special Yarn. The area having the Special Yarn undergoes heat processing or heat pressing, such that the Special Yarn melts and fuses with its surrounding, and results in a non-folding/non-raveling/non-rolling edge line or edge-zone of the garment-region.
In garment-region 703, the Special Yarn is a set of generally-parallel yet spaced-apart Special Yarns (e.g., with at least one thread of Other Yarn between each two neighboring Special Yarn threads), that are generally slanted or diagonal relative to the actual edge of the garment region, located at (or near) the edge or the ending of the garment-region; whereas the remainder of the garment-region is formed of Other Yarn and does not comprise the Special Yarn. The area having the Special Yarn undergoes heat processing or heat pressing, such that the Special Yarn melts and fuses with its surrounding, and results in a non-folding/non-raveling/non-rolling edge line or edge-zone of the garment-region.
In garment-region 704, the Special Yarn is a set of generally-parallel yet spaced-apart Special Yarns (e.g., with at least one thread of Other Yarn between each two neighboring Special Yarn threads), that are generally slanted or diagonal relative to the actual edge of the garment region; and which are crisscrossed or interwoven or traversed by a similar and generally-perpendicular set of Special Yarns; located at (or near) the edge or the ending of the garment-region; whereas the remainder of the garment-region is formed of Other Yarn and does not comprise the Special Yarn. The area having the Special Yarn undergoes heat processing or heat pressing, such that the Special Yarn melts and fuses with its surrounding, and results in a non-folding/non-raveling/non-rolling edge line or edge-zone of the garment-region.
In garment-region 705, the Special Yarn is a set of generally-parallel yet spaced-apart Special Yarns (e.g., with at least one thread of Other Yarn between each two neighboring Special Yarn threads), that are curly or wave-shaped, located at (or near) the edge or the ending of the garment-region; whereas the remainder of the garment-region is formed of Other Yarn and does not comprise the Special Yarn. The area having the Special Yarn undergoes heat processing or heat pressing, such that the Special Yarn melts and fuses with its surrounding, and results in a non-folding/non-raveling/non-rolling edge line or edge-zone of the garment-region.
In garment-region 706, the Special Yarn is a set of generally-parallel yet spaced-apart Special Yarns (e.g., with at least one thread of Other Yarn between each two neighboring Special Yarn threads), that are zigzag shaped, located at (or near) the edge or the ending of the garment-region; whereas the remainder of the garment-region is formed of Other Yarn and does not comprise the Special Yarn. The area having the Special Yarn undergoes heat processing or heat pressing, such that the Special Yarn melts and fuses with its surrounding, and results in a non-folding/non-raveling/non-rolling edge line or edge-zone of the garment-region.
In garment-region 707, the Special Yarn is a single yarn knitted as a convex or an outwardly-facing curve or curvature, at (or near) the edge or the ending of the garment-region; or is a set or a batch of such convex threads of Special Yarns that are knitted together at the same direction (e.g., generally parallel to each other, forming a thicker convex yarn), at (or near) the edge or the ending of the garment-region; whereas the remainder of the garment-region is formed of Other Yarn and does not comprise the Special Yarn. The area having the Special Yarn undergoes heat processing or heat pressing, such that the Special Yarn melts and fuses with its surrounding, and results in a non-folding/non-raveling/non-rolling edge line or edge-zone of the garment-region.
In garment-region 708, the Special Yarn is a single yarn knitted as a concave or an inwardly-facing curve or curvature, at (or near) the edge or the ending of the garment-region; or is a set or a batch of such concave threads of Special Yarns that are knitted together at the same direction (e.g., generally parallel to each other, forming a thicker concave yarn), at (or near) the edge or the ending of the garment-region; whereas the remainder of the garment-region is formed of Other Yarn and does not comprise the Special Yarn. The area having the Special Yarn undergoes heat processing or heat pressing, such that the Special Yarn melts and fuses with its surrounding, and results in a non-folding/non-raveling/non-rolling edge line or edge-zone of the garment-region.
In garment-region 709, the Special Yarn is a single yarn knitted as a zigzag ending, at (or near) the edge or the ending of the garment-region; or is a set or a batch of such zigzag threads of Special Yarns that are knitted together at the same direction (e.g., generally parallel to each other, forming a thicker zigzag yarn), at (or near) the edge or the ending of the garment-region; whereas the remainder of the garment-region is formed of Other Yarn and does not comprise the Special Yarn. The area having the Special Yarn undergoes heat processing or heat pressing, such that the Special Yarn melts and fuses with its surrounding, and results in a non-folding/non-raveling/non-rolling edge line or edge-zone of the garment-region.
In garment-region 710, the Special Yarn is a single yarn knitted as a wave-shaped or wavy or curly ending, at (or near) the edge or the ending of the garment-region; or is a set or a batch of such wavy or curly threads of Special Yarns that are knitted together at the same direction (e.g., generally parallel to each other, forming a thicker wavy or curly yarn), at (or near) the edge or the ending of the garment-region; whereas the remainder of the garment-region is formed of Other Yarn and does not comprise the Special Yarn. The area having the Special Yarn undergoes heat processing or heat pressing, such that the Special Yarn melts and fuses with its surrounding, and results in a non-folding/non-raveling/non-rolling edge line or edge-zone of the garment-region.
In garment-region 711, the Special Yarn is a single yarn knitted as a zigzag ending, at (or near) the edge or the ending of the garment-region; or is a set or a batch of such zigzag threads of Special Yarns that are knitted together at the same direction (e.g., generally parallel to each other, forming a thicker zigzag yarn), at (or near) the edge or the ending of the garment-region; and also, a set of Special Yarns is further knitted as generally-parallel threads near such edge or ending; whereas the remainder of the garment-region is formed of Other Yarn and does not comprise the Special Yarn. The area having the Special Yarn undergoes heat processing or heat pressing, such that the Special Yarn melts and fuses with its surrounding, and results in a non-folding/non-raveling/non-rolling edge line or edge-zone of the garment-region.
In garment-region 712, the Special Yarn is a single yarn knitted as a curly or wavy ending, at (or near) the edge or the ending of the garment-region; or is a set or a batch of such curly or wavy threads of Special Yarns that are knitted together at the same direction (e.g., generally parallel to each other, forming a thicker curly or wavy yarn), at (or near) the edge or the ending of the garment-region; and also, a set of Special Yarns is further knitted as generally-parallel curved or concave or convex threads near such edge or ending; whereas the remainder of the garment-region is formed of Other Yarn and does not comprise the Special Yarn. The area having the Special Yarn undergoes heat processing or heat pressing, such that the Special Yarn melts and fuses with its surrounding, and results in a non-folding/non-raveling/non-rolling edge line or edge-zone of the garment-region.
In garment-region 713, a batch of curved (e.g., convex) Special Yarns is used near the edge or the ending of the garment-region. The edge itself is also a Special Yarn (in some embodiments); or, the edge itself is formed of Other Yarn (in other embodiments). The remainder of the garment-region is formed of Other Yarn and does not comprise the Special Yarn. The area having the Special Yarn undergoes heat processing or heat pressing, such that the Special Yarn melts and fuses with its surrounding, and results in a non-folding/non-raveling/non-rolling edge line or edge-zone of the garment-region.
In garment-region 714, a batch of curved (e.g., concave) Special Yarns is used near the edge or the ending of the garment-region. The edge itself is also a Special Yarn (in some embodiments); or, the edge itself is formed of Other Yarn (in other embodiments). The remainder of the garment-region is formed of Other Yarn and does not comprise the Special Yarn. The area having the Special Yarn undergoes heat processing or heat pressing, such that the Special Yarn melts and fuses with its surrounding, and results in a non-folding/non-raveling/non-rolling edge line or edge-zone of the garment-region.
Reference is made to FIGS. 10A and 10B, which are schematic illustrations of two garment- portions 800 and 805, respectively, in accordance with some demonstrative embodiments of the present invention. Garment-portion 800 demonstrates a stage in production of a bra or brassiere or sports-bra or tank-top; Garment-portion 805 demonstrates another, subsequent stage in production of such bra or brassiere or sports-bra or tank-top.
As demonstrated in FIG. 10A, a generally tube-shaped or cylindrical garment-portion is knitted, having a first-region 801 and an identical and symmetrical second-region 802. Each one of the two region 801-802 includes regions for two breast cups (C1); regions for fabric located above the breast cups (P1); regions for fabric located below the breast cups (L1); and regions of fabric that are intended to be cut-away and discarded or disposed (K1). In some embodiments, regions P1 and/or L1 are knitted by Floating the Special Yarn (the special melting yarn), with Laid In knitting technique incorporating therein the Special Yarn, with or without other yarns; in some implementations, the Special Yarn is knitted there every second row of knitting, in Laid In knitting technique; or, in other implementations, in the other alternative rows, will be knitted with the other yarns (not Special Yarn) with or without the Special Yarn, in a regular knitting way, such as plain knitting or pique or rib or mesh. In some embodiments, the cup regions (C1) may not include Special Yarn; rather, they may include other yarn or knitted fabric or material; but in other embodiments, the cup regions (C1) will include the Special yarn (special melting yarn) every knitting row, or every second knitting row, but it will not be Floated by Laid In knitting technique, but rather, it is knitted in a regular knitting way (non floated, non-laid-in), such as plain knitting, or pique, or rib, or mesh, which may subsequently be subject to molding or to other suitable incorporation of cup forming components. The two regions 801 and 802 mirror each other.
As demonstrated in FIG. 10B, the two regions may be folded, one on the other, and heat-and-pressure is applied to the folded item, such that a unified double-layer product 805 is formed, and all the regions P1 and L1 of layer 801 will be bonded to all the corresponding regions P1 and L1 of layer 802, and by that will increase or improve the support in the regions where the Special Yarn was floated by the Laid In knitting technique.
Other suitable folding techniques may be used; for example, folding in three or in four, to obtain a different number of layers, or different levels of support or elasticity. In some embodiments, the density or the amount of Special Yarn threads in a particular portion of region 801, may be different from the density or the amount of Special Yarn threads in the corresponding (mirroring, symmetrical) portion of region 802, in order to reach a particular level of desired support or rigidity or elasticity or other characteristics.
In some embodiments, the Special Yarn may be, or may be formed of, or may comprise, for example: a particular Spandex yarn or Spandex-type yarn, Lycra, Roica, Creora, or the yarn known as “X4zol™-J Fiber”; a TPU fiber, a TPU yarn; a melting yarn; an elastomeric mono-filament yarn or thread or fiber; a TPU fiber or an elastomeric mono-filament (or double-filament, or triple-filament, or quadruple-filament, or multi-filament or multi-filament) that is produced through melt extrusion and which does not require the use of solvents.
In some embodiments, the Special Yarn may be, or may be formed of, or may comprise, for example: a melt spun thermoplastic polyurethane polymer mono-filament, comprising a crosslinking agent and exemplified by X4zol™-J as available from Lubrizol Advanced Materials Inc of Cleveland, Ohio, USA.
In some embodiments, the Special Yarn may be, or may be formed of, or may comprise, for example: a melt spun lightly crosslinked thermoplastic polyurethane polymer mono-filament, exemplified by X4zol™-J as available from Lubrizol Advanced Materials Inc of Cleveland, Ohio, USA.
In some embodiments, the Special Yarn may be, or may be formed of, or may comprise, for example: a fiber or a yarn or a thread that is described in patent number U.S. Pat. No. 7,799,255 B2 and/or in patent number U.S. Pat. No. 7,763,351 B2, both of which are hereby incorporated by reference, as those two patents may further provide to a person of ordinary skill in the art full enabling details of how to manufacture or make or obtain the yarn or fiber to be used as Special Yarn and/or which properties or characteristics such Special Yarn has or may have.
In some embodiments, the Special Yarn is or comprises monofilament melt spun fibers having fiber thickness of 20 denier, or 30 denier, or 40 denier, or 70 denier, or 140 denier, or 210 denier, or 360 denier, or 400 denier; or under 500 denier; or in the range of 20 to 400 denier; or in the range of 20 to 360 denier; or in the range of 20 to 100 denier; or in the range of 20 to 140 denier; prepared from (or consisting of, or made of, or being) a thermoplastic polyurethane (TPU) polymer composition.
In some embodiments, the Special Yarn is or comprises monofilament melt spun fibers having fiber thickness in the range of 20 to 400 denier (or in some embodiments, in the range of 20 to 360 denier; or in the range of 20 to 140 denier); prepared from (or consisting of, or made of, or being) a thermoplastic polyurethane (TPU) polymer composition.
In some embodiments, the fibers of the Special Yarn comprise the reaction product of at least one hydroxyl terminated intermediate with at least one polyisocyanate, at least one chain extender, and at least one crosslinking agent.
In some embodiments, the at least one hydroxyl terminated intermediate is selected from the group consisting of: a hydroxyl terminated polyester, a hydroxyl terminated polyether, and a hydroxyl terminated polycarbonate.
In some embodiments, the polymer intermediate comprises a blend or a mixture of two or more polyether hydroxyl terminated intermediates of different molecular weights; wherein a first polymer intermediate has a molecular weight in the range of 700 to 1,500 Daltons; wherein a second polymer intermediate has a molecular weight in the range of 1,500 to 4,000 Daltons.
In some embodiments, the polyisocyanate is of formula R(NCO)n, where n is 2, or wherein n is 3, or wherein n is 4, or wherein n is in the range of 2 to 4. Examples of suitable aromatic diisocyanates may include: diphenyl methane-4,4′-diisocyanate (MDI), H₁₂MDI, m-xylylene diisocyanate (XDI), m-tetramethyl xylylene diisocyanate (TMXDI), phenylene-1,4-diisocyanate (PPDI), 1,5-naphthalene diisocyanate (NDI), and diphenylmethane-3,3′-dimethoxy-4,4′-diisocyanate (TODI). Examples of suitable aliphatic diisocyanates include isophorone diisocyanate (IPDI), 1,4-cyclohexyl diisocyanate (CHDI), hexamethylene diisocyanate (HDI), 1,6-diisocyanato-2,2,4,4-tetramethyl hexane (TMDI), 1,10-decane diisocyanate, and trans-dicyclohexylmethane diisocyanate (HMDI).
In some embodiments, the chain extender is a lower aliphatic or short chain glycols having carbon atoms in the range of 2 to 10 carbon atoms, such as a glycol selected from the group consisting of ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, triethylene glycol, cis-trans-isomers of cyclohexyl dimethylol, neopentyl glycol, 1,4-butanediol, 1,6-hexandiol, 1,3-butanediol, and 1,5-pentanediol. In some embodiments, the chain extender is an aliphatic glycol such as benzene glycol (HQEE) or xylenene glycols. In some embodiments, the chain extender is benzye glycol, or a blend of benzene glycol with hydroxy ethyl resorcinol (HER).
In some embodiments, a co-chain extender is used together with the chain extender described above.
In some embodiments, the hydroxyl terminated intermediate, polyisocyanate and the chain extender are reacted in the presence of a catalyst.
Non-limiting examples of suitable catalysts include: alkyl ethers or alkyl thiol ethers of bismuth or tin, wherein the alkyl portion has from 1 to 20 carbon atoms, such as bismuth octoate, bismuth laurate, and the like. Some suitable catalysts include tin catalysts such as stannous octoate, dibutyltin dioctoate, dibutyltin dilaurate, or the like.
In some embodiments, a crosslinking agent is used to crosslink the TPU polymer during the spinning process. The crosslinking agent is, for example, a pre-polymer of a hydroxyl terminated intermediate that is a polyether, polyester, polycarbonate, polycaprolactone, or mixture thereof reacted with a polyisocyanate, more preferably a polyester or polyether. The polyisocyanate used to make the crosslinking agent may be the same as described above in making the TPU polymer. In some embodiments, the crosslinking agent has a molecular weight in the range of 1,000 to 10,000 Daltons, or in the range of 1,500 to 2,800 Daltons.
According to some embodiments, the fibers comprise the reaction product of a blend of at least two polyether hydroxyl terminated intermediates having different molecular weights; at least one polyisocyanate; at least one chain extender and at least one crosslinking agent, wherein the TPU in the fiber has a 300% modulus of from 1,571 to 1,861 psi, an elongation (or a maximum elongation when a maximum force is applied before the thread is torn or broken) in the range of 583% to 652%, and a tenacity of from 5,200 to 5,690 psi.
In some such embodiments, a first of the at least two polyether hydroxyl terminated intermediates has a molecular weight of 1,000 Daltons; and the second of the at least two polyether hydroxyl terminated intermediates has a molecular weight of 2,000 Daltons; and the chain extender is benzene glycol. In some embodiments, the blend further comprises an antioxidant, an Ultra-Violet (UV) stabilizer, and a lubricant; and the TPU formed has a molecular weight of 150,000 Daltons.
In some embodiments, the fibers are produced by a melt spinning process comprising, for example: melting the TPU polymer; adding a cross-linking agent to the melted TPU polymer to provide a TPU composition having enhanced elastic properties; introducing the TPU composition into a manifold, wherein the manifold divides the TPU composition into multiple melt streams; feeding each of the multiple melt streams to multiple spinnerets using a melt pump, wherein each spinneret has an opening through which the melt exists the spinneret to form the fibers; cooling the fibers by passing them through a horizontal or a substantially horizontal cooling unit or cooling step, such as a water bath; and winding the fibers onto a roll or bobbin.
In some embodiments, the TPU polymer prior to melting is in pellet form having a Shore A hardness in the range of 65 A to 95 A.
In some embodiments, a water bath is used in the cooling step, and the temperature of the water in the bath is in the range of 0 to 35 degrees Celsius.
In some embodiments, anti-tack additives such as oils (e.g., silicone oils) are added to the surface of the fibers, after and/or during cooling, and/or immediately prior to winding into rolls or bobbins.
In some embodiments, uniform mixing of the TPU polymer with the crosslinking is performed. Such uniform mixing may be achieved with a dynamic mixer or optionally using a static mixer. Mixing of the TPU polymer with the crosslinking agent is performed at a temperature of 200 to 240 degrees Celsius, or 210 to 225 degrees Celsius.
During spinning, the temperature of the polymer melt in the spinneret is higher than the melting point of the polymer; such as, it is higher than the melting point of the polymer by 10 to 20 degrees Celsius.
In some embodiments, the fibers are combined with other fibers, including natural fibers and/or synthetic fibers, such as cotton or polyester, typically by weaving or knitting. In some embodiments, the resulting fabric comprises about 5 to 40 percent of TPU fibers, and the remainder are other (e.g., non-TPU) fibers.
In some embodiments, the Special Yarn is manufactured in a melt spinning process which produces an elastic tape having a thickness in the range of 0.001 to 0.10 inch, and having a width in the range of 0.1 to 2.0 inches. The process comprises: (a) feeding to a melt mixing machine, a preformed TPU polymer consisting of a thermoplastic polyurethane polymer in pellet form having a Shore A hardness in the range of 65 A to 95 A; (b) melting said TPU polymer pellets to form a TPU polymer melt; (c) adding a cross-linking agent to said TPU polymer melt, wherein the amount of said crosslinking agent added is from 2.0% to 20.0% by weight of the final weight of said tape, and wherein said crosslinking agent has a number average molecular weight (Mn) of from 1,000 to 10,000 Daltons; (d) mixing said crosslinking agent with said TPU polymer melt; (e) feeding said TPU polymer melt to a manifold; (f) dividing said TPU polymer melt into multiple melt streams by using said manifold; (g) feeding each of said multiple melt streams to multiple spinnerets by using a melt pump for each melt stream, wherein each spinneret has a single opening where the melt exits to form the desired shape of said tape; (h) cooling the tape by passing said tape through a substantially horizontal water cooling bath, or via a substantially vertical cooling bath, wherein said water cooling bath is located from 1.0 inch to 2.0 feet from the exit of said each spinneret; and (i) winding said tape into a roll.
In some embodiments, the amount of said crosslinking agent added is from 8.0% to 15.0% by weight of the final weight of said tape. In some embodiments, the amount of said crosslinking agent added is from 10% to 13.0% by weight of the final weight of said tape. In some embodiments, said crosslinking agent has a number average molecular weight (Mn) of from 1,500 to 2,800 Daltons. In some embodiments, said crosslinking agent is mixed with said TPU polymer melt with a dynamic mixer or a static mixer. In some embodiments, said TPU polymer has Mw of from 150,000 to 350,000 Daltons. In some embodiments, said TPU polymer has a Shore A hardness of from 75 A to 85 A. In some embodiments, said melt mixing machine is an extruder.
In some embodiments, the Special Yarn is a melt spun TPU monofilament fiber having a size or thickness in the range of 20 to 400 denier, or an elastic tape; wherein said fiber or said tape comprises the reaction product of: (a) a blend of at least two polyether hydroxyl terminated intermediates, wherein said polyether have different Mn values; (b) at least one chain extender; (c) at least one polyisocyanate; and (d) at least one crosslinking agent; wherein said TPU in said monofilament fiber or said tape has a 300% modulus of from 1,571 to 1,861 psi, an elongation (or a maximum elongation under maximum pressure that does not yet tear or break the thread) of from 583% to 652%, and a tenacity of from 5,200 to 5,690 psi.
In some embodiments, said two polyethers have a weighted average Mn greater than 1,500 Daltons. In some embodiments, said fiber or said tape has a Mw value of from 200,000 to 800,000 Daltons, or from 300,000 to 450,000 Daltons.
In some embodiments, said chain extender is benzene glycol (HQEE). In some embodiments, said chain extender is a blend of benzene glycol (HQEE) and hydroxyl ethyl resorcinol (HER). In some embodiments, said polyisocyanate is a diisocyanate. In some embodiments, said crosslinking agent has a Mn of from 1,000 to 10,000 Daltons, or from 1,500 to 2,800 Daltons. In some embodiments, said fiber has a size or thickness of 20 denier, or 30 denier, or 40 denier, or 70 denier, or 140 denier, or 210 denier, or 360 denier, or 400 denier; or under 500 denier; or in the range of 20 to 400 denier; or in the range of 20 to 360 denier; or in the range of 20 to 100 denier.
In some embodiments, said tape has a thickness of from 0.001 inch to 0.10 inch; and a width of from 0.1 inch to 2.0 inches. In some embodiments, said crosslinking agent is used at a level of from 2.0 to 20.0 weight percent of said fiber or said tape.
In some embodiments, the Special Yarn is a melt-spun fiber made from a resin comprising the reaction product of (i) a hydroxyl terminated polyester intermediate derived from a dicarboxylic acid and a blend of at least two alkylene glycols, wherein two of the alkylene glycols have a number average molecular weight that differs by at least 20 percent; (ii) a diisocyanate; and (iii) a linear alkylene glycol chain extender; wherein the resin has a weight average molecular weight of at least 600,000; and wherein the resin is further reacted with: (iv) an agent comprising the reaction product of a polyalkylene ether glycol and a diisocyanate; wherein said fiber has a weight average molecular weight of at least 700,000.
In some embodiments, component (iv) is derived from a polyalkylene ether glycol comprising polytetramethylene ether glycol. In some embodiments, component (iv) is derived from a diisocyanate comprising methylene diphenyl diisocyanate. In some embodiments, component (i) is derived from a carboxylic acid comprising adipic acid. In some embodiments, component (i) is derived from a 25:75 to 75:25 mixture, on a weight basis, of 1,4-butanediol and 1,6-hexanediol. In some embodiments, component (ii) comprises methylene diphenyl diisocyanate. In some embodiments, component (iii) comprises 1,4-butanediol, 1,6-hexanediol, or combinations thereof.
In some embodiments, the Special Yarn is produced by the following method of fiber production: (I) preparing an elastomer resin in an internal mixing device; wherein said elastomer resin is prepared by reacting: a hydroxyl terminated polyester intermediate derived from a dicarboxylic acid, and a blend of at least two alkylene glycols; wherein two of the alkylene glycols have a number average molecular weight that differs by at least 20 percent; (ii) a diisocyanate; and (iii) a linear alkylene glycol chain extender; wherein the resulting resin has a weight average molecular weight of at least 600,000; (II) further reacting the resin composition with (iv) an agent comprising the reaction product of a polyalkylene ether glycol and a diisocyanate; (III) processing said elastomer resin into a fiber, film, or hose wherein said fiber, film, or hose has a weight average molecular weight of at least 700,000.
Some embodiments of the present invention include a method of producing a fabric or a garment having a seamless finished edge. The method may include: (a) providing a fabric having a plurality of fibers, at least some of said fibers having free ends terminating at an edge of said fabric; (b) disposing or injecting or adding or inserting or mixing or 3D-printing or knitting or adding a melt spun thermoplastic polyurethane polymer monofilament over or across or near or at the edge of said fabric, so that said polymer engages with the free ends of said fibers at or near the edge of said fabric; (c) simultaneously applying pressure and heat to said polymer for finishing the edge of said fabric and creating a non-raveling non-rolling edge; wherein said polymer comprises a crosslinking agent.
Some embodiments include a garment having a seamless and/or non-raveling and/or non-rolling finished edge. The garment comprises: (a) a cut pattern piece made of fibers, wherein at least some of said fibers have free ends that terminate at or near an edge of said cut pattern piece; (b) a heated and pressed melt spun lightly crosslinked thermoplastic polyurethane polymer monofilament material, which is in contact with (or, crosses) the free ends of said fibers, at or near the edge of said cut pattern piece; wherein said heated and pressed polymer material provides a finished edge to said cut pattern piece that is devoid of a knitted-in edge or folded-over edge; wherein said polymer comprises a crosslinking agent.
The discussion herein may relate, for demonstrative purposes, to a shirt or to pants or to other particular garments. However, the invention may similarly comprise, or may be used in conjunction with, other garments and/or undergarments and/or clothing articles; for example, panties, boxers, briefs, underwear, shorts, sportswear, active-wear, yoga pants, aerobic pants, training pants, lingerie, thongs, shaper, body-shaper, shaping garment, shaping undergarment, shape-wear, active-wear, sports-wear, form-fitting undergarment, form-fitting garment, swimsuit, swim-wear, pants, trousers, socks, shirt, sweat-shirt, jacket, coat, apron, long-sleeve shirt, short-sleeve shirt, Polo shirt, T-shirt, skirt, dress, sports-skirt, tennis skirt, or the like.
Some embodiments include a garment comprising: a particular garment-region made of knitted fabric, wherein a majority of threads of said knitted fabric in said particular garment-region are yarns other than a thermally-fused thermoplastic yarn, wherein said yarns are one or more yarns selected from the group consisting of: cotton, polyester, nylon, polypropylene, cellulose, polyurethane; wherein at least one thread of said knitted fabric in said particular garment-region is a thermally-fused thermoplastic yarn that is knitted integrally in said knitted fabric and is located within N millimeters from an edge or an opening of said garment, wherein N is in the range of 0 to 10 millimeters; wherein the edge or the opening of said particular garment-region is unravel free and is roll-free due to inclusion of or proximity to said thermally-fused thermoplastic yarn in said knitted fabric in said particular garment-region.
In some embodiments the thermally-fused thermoplastic yarn is knitted in said particular garment region with other yarn(s); and the garment-region undergoes heat-and-press treatment, which hardens and/or changes the elasticity and/or the rigidity of the said thermally-fused thermoplastic yarn in its post heat-and-press status.
In some embodiments the said thermally-fused thermoplastic yarn (in a pre-fusion state, or in a pre heat-and-press state as a non-heated yarn) is knitted in said particular garment region with other yarn(s); and the garment-region does not undergo heat-and-press treatment; yet, realized the Applicants, in some embodiments, the inclusion of the thermoplastic yarn as a knitted yarn in that area may suffice to change the elasticity and/or the rigidity of the garment-region even without the heat-and-press process.
In some embodiments, the garment is a garment selected from the group consisting of: pants, leggings, tights, sports pants, yoga pants, shorts, boxers, underwear; wherein said particular garment-region is bordering a leg opening of said garment; wherein at least one thread of said knitted fabric in said particular garment-region is a thermally-fused thermoplastic yarn that is knitted integrally in said knitted fabric and is located within N millimeters from an edge of said leg opening, wherein N is in the range of 0 to 10 millimeters.
In some embodiments, the garment is a garment selected from the group consisting of: pants, leggings, tights, sports pants, yoga pants, shorts, boxers, underwear; wherein said particular garment-region is bordering a waist-band of said garment; wherein at least one thread of said knitted fabric in said particular garment-region is a thermally-fused thermoplastic yarn that is knitted integrally in said knitted fabric and is located within N millimeters from an edge of said waist-band, wherein N is in the range of 0 to 10 millimeters.
In some embodiments, the garment is a garment selected from the group consisting of: short-sleeve shirt, long-sleeve shirt, semi-long sleeve shirt, sleeveless shirt, tank top; wherein said particular garment-region is bordering an arm opening of said garment; wherein at least one thread of said knitted fabric in said particular garment-region is a thermally-fused thermoplastic yarn that is knitted integrally in said knitted fabric and is located within N millimeters from an edge of said arm opening, wherein N is in the range of 0 to 10 millimeters.
In some embodiments, the garment is a garment selected from the group consisting of: short-sleeve shirt, long-sleeve shirt, semi-long sleeve shirt, sleeveless shirt, tank top; wherein said particular garment-region is bordering a neck opening opening of said garment; wherein at least one thread of said knitted fabric in said particular garment-region is a thermally-fused thermoplastic yarn that is knitted integrally in said knitted fabric and is located within N millimeters from an edge of said neck opening, wherein N is in the range of 0 to 10 millimeters.
In some embodiments, the garment is a garment selected from the group consisting of: bra, brassiere, sports bra; wherein said particular garment-region is a shoulder strap of said garment; wherein at least one thread of said knitted fabric in said particular garment-region is a thermally-fused thermoplastic yarn that is knitted integrally in said knitted fabric and is located within N millimeters from an edge of said shoulder strap, wherein N is in the range of 0 to 10 millimeters.
In some embodiments, the garment is a garment selected from the group consisting of: bra, brassiere, sports bra; wherein said particular garment-region comprises a front band located under the breast cups of said garment; wherein at least one thread of said knitted fabric in said particular garment-region is a thermally-fused thermoplastic yarn that is knitted integrally in said knitted fabric and is located within N millimeters from an edge of said front band, wherein N is in the range of 0 to 10 millimeters.
In some embodiments, the garment is a garment selected from the group consisting of: bra, brassiere, sports bra; wherein said particular garment-region is a tubular portion of said garment, and comprises two folded, symmetrical, heat-and-pressure treated, layers of tubular knitted fabric that comprise said thermally-fused thermoplastic yarn that is knitted integrally therein. In some embodiments, said thermally-fused thermoplastic yarn that is integrally knitted in said fabric of said particular garment-region and is parallel to an edge of said particular garment-region. In some embodiments, said thermally-fused thermoplastic yarn that is integrally knitted in said fabric of said particular garment-region and is perpendicular to an edge of said particular garment-region. In some embodiments, said thermally-fused thermoplastic yarn that is integrally knitted in said fabric of said particular garment-region and is slanted at an angle in a range of 1 to 89 degrees relative to an edge of said particular garment-region.
In some embodiments, said thermally-fused thermoplastic yarn is a set of at least two, spaced-apart, thermally-fused thermoplastic yarns that are parallel to each other and that are integrally knitted in said fabric of said particular garment-region and are parallel to an edge of said particular garment-region.
In some embodiments, said thermally-fused thermoplastic yarn is a set of at least two, spaced-apart, thermally-fused thermoplastic yarns that are parallel to each other and that are integrally knitted in said fabric of said particular garment-region and are perpendicular to an edge of said particular garment-region.
In some embodiments, said thermally-fused thermoplastic yarn is a set of at least two, spaced-apart, thermally-fused thermoplastic yarns that are parallel to each other and that are integrally knitted in said fabric of said particular garment-region and are slanted at an angle in a range of 1 to 89 degrees relative to an edge of said particular garment-region.
In some embodiments, said thermally-fused thermoplastic yarn is a set of at least two, spaced-apart, thermally-fused thermoplastic yarns that are parallel to each other and that are integrally knitted in crisscross structure in said fabric of said particular garment-region within N millimeters from an edge of said particular garment-region, wherein N is in the range of 0 to 10 millimeters.
In some embodiments, said thermally-fused thermoplastic yarn is a set of at least two, spaced-apart, curved, non-straight, thermally-fused thermoplastic yarns that are parallel to each other and that are integrally knitted in a structure of curved parallel lines in said fabric of said particular garment-region within N millimeters from an edge of said particular garment-region, wherein N is in the range of 0 to 10 millimeters.
In some embodiments, said thermally-fused thermoplastic yarn that is integrally knitted in said fabric of said particular garment-region is touching only a portion, and not all, of the edge of said particular garment-region. In some embodiments, said thermally-fused thermoplastic yarn that is integrally knitted in said fabric of said particular garment-region is touching an entirety of the edge of said particular garment-region.
In some embodiments, said thermally-fused thermoplastic yarn is a thermally-fused thermoplastic yarn formed from monofilament melt spun fibers which are pressure-and-heat stamped and which have fiber thickness in a range of 20 denier to 400 denier.
In some embodiments, said thermally-fused thermoplastic yarn is a thermally-fused thermoplastic yarn formed from monofilament melt spun fibers which are pressure-and-heat stamped and which have fiber thickness in a range of 20 denier to 100 denier.
In some embodiments, said thermally-fused thermoplastic yarn is integrally knitted into said knitted fabric in a structure selected from the group consisting of: single jersey structure, miss knitting structure, tack knitting structure, mesh knitting structure, a combination of two or more of said structures.
In some embodiments, an edge of said particular garment-region is a finished seamless edge that is non-unraveling and is roll-free.
In some embodiments, said thermally-fused thermoplastic yarn is a melt spun thermoplastic polyurethane polymer monofilament comprising a crosslinking agent and having a modulus of 300% in a range of 1,571 psi to 1,861 psi.
In some embodiments, said thermally-fused thermoplastic yarn is a melt spun lightly-crosslinked thermoplastic polyurethane polymer monofilament having a modulus of 300% in a range of 1,550 psi to 1,880 psi; wherein said lightly-crosslinked thermoplastic polyurethane polymer monofilament comprises a crosslinking agent of 8% to 15% by weight of a final weight of said thermally-fused thermoplastic yarn; wherein said crosslinking agent has a Number Average Molecular Weight (Mn) in a range of 1,500 to 2,800 Daltons.
In some embodiments, said thermally-fused thermoplastic yarn is a melt spun TPU monofilament fiber having a thickness in a range of 20 denier to 400 denier; wherein said fiber comprises a reaction product of: (A) a blend of at least two polyether hydroxyl terminated intermediates, wherein said polyether hydroxyl terminated intermediates have different Number Value Molecular Weight (Mn) values; (B) at least one chain extender; (C) at least one polyisocyanate; and (D) at least one crosslinking agent; wherein said TPU in said monofilament fiber has a 300% modulus of from 1,500 to 1,900 psi, and a maximum elongation of from 550% to 680%, and a tenacity of from 5,000 to 5,700 psi; wherein at least one of said polyether hydroxyl terminated intermediates has a Number Value Molecular Weight (Mn) value in a range of 700 to 1,500 Daltons; wherein at least one other of said polyether hydroxyl terminated intermediates has a Number Value Molecular Weight (Mn) value in a range of 1,500 to 4,000 Daltons; wherein said melt spun TPU monofilament fiber has a Molecular Weight (Mw) in a range of 250,000 to 500,000 Daltons. wherein said melt spun TPU monofilament fiber has a Shore A hardness in a range of 75 A to 85 A.
In some embodiments, said thermally-fused thermoplastic yarn provides to said particular garment-region an improved body grip capability, relative to body grip capability of other garment-regions of said garment that exclude said thermally-fused thermoplastic yarn; wherein said thermally-fused thermoplastic yarn provides to said particular garment-region an improved non-unraveling capability, relative to non-unraveling capability of other garment-regions of said garment that exclude said thermally-fused thermoplastic yarn; wherein said thermally-fused thermoplastic yarn provides to said particular garment-region an improved roll-free capability, relative to roll-free capability of other garment-regions of said garment that exclude said thermally-fused thermoplastic yarn.
In some embodiments, a method of producing a garment comprises: (a) knitting a particular garment-region from yarns, wherein a majority of threads of said knitted fabric in said particular garment-region are yarns other than a thermally-fused thermoplastic yarn, wherein said yarns are one or more yarns selected from the group consisting of: cotton, polyester, nylon, polypropylene, cellulose, polyurethane; wherein at least one thread of said knitted fabric in said particular garment-region is a thermally-fused thermoplastic yarn that is knitted integrally in said knitted fabric and is located within N millimeters from an edge or an opening of said garment, wherein N is in the range of 0 to 10 millimeters; (b) applying a heat-and-pressure treatment to said particular garment-region, for a pre-defined time-period, and causing said thermally-fused thermoplastic yarn to at least partially melt and change its physical properties of elongation, elasticity and/or tenacity due to said heat-and-pressure treatment, and causing an edge or an opening of said particular garment-region to become unravel free and roll-free due to inclusion of or proximity to said thermally-fused thermoplastic yarn in said knitted fabric in said particular garment-region that was subject to said heat-and-pressure treatment.
In some embodiments, a process for producing a garment comprises: (a) producing a particular garment-region having a seamless finished edge that is roll-free and unravel-free; wherein step (a) is performed by: (a1) knitting a fabric having a plurality of fibers, wherein at least some of said fibers have free ends terminating at an edge of said fabric; (a2) disposing a melt spun thermoplastic polyurethane polymer monofilament over the edge of said fabric, wherein said melt spun thermoplastic polyurethane polymer monofilament engages with said free ends of said fibers at the edge of said fabric; (a3) applying a heat-and-pressure treatment to said melt spun thermoplastic polyurethane polymer monofilament for a pre-defined time period; wherein said melt spun thermoplastic polyurethane polymer monofilament comprises a crosslinking agent in a range of 8% to 15% by weight of a final weight of said melt spun thermoplastic polyurethane polymer monofilament; wherein said melt spun thermoplastic polyurethane polymer monofilament has a 300% modulus of from 1,500 to 1,900 psi.
In some embodiments, a system of producing a garment or a fabric comprises: (a) knitting machine, associated with a knitting controller, configured to knit a particular garment-region from yarns, wherein a majority of threads of said knitted fabric in said particular garment-region are yarns other than a thermally-fused thermoplastic yarn, wherein said yarns are one or more yarns selected from the group consisting of: cotton, polyester, nylon, polypropylene, cellulose, polyurethane; wherein at least one thread of said knitted fabric in said particular garment-region is a thermally-fused thermoplastic yarn that is knitted integrally in said knitted fabric and is located within N millimeters from an edge or an opening of said garment, wherein N is in the range of 0 to 10 millimeters; (b) a heat-and-press machine, configured to apply a heat-and-pressure treatment to said particular garment-region, for a pre-defined time-period, and causing said thermally-fused thermoplastic yarn to at least partially melt and change its physical properties of elongation, elasticity and/or tenacity due to said heat-and-pressure treatment, and causing an edge or an opening of said particular garment-region to become unravel free and roll-free due to inclusion of or proximity to said thermally-fused thermoplastic yarn in said knitted fabric in said particular garment-region that was subject to said heat-and-pressure treatment.
Some embodiments may be implemented by using a machine or an automated or semi-automatic production line, which may comprise, for example: cutting unit, welding unit, bonding unit, ultrasonic operations unit, gluing unit, conveyor belt, robotic arm, control unit, workstation; as well as suitable hardware components and/or software components, for example, processor to execute code, memory unit, storage unit, input unit (keyboard, mouse, touch-screen), output unit (screen, touch-screen), modems, transceivers or transmitters or receivers, wireless and/or wired communication links and/or transceivers or transmitters or receivers, power sources, Operating System (OS) and suitable applications, or the like.
Some embodiments may be used in conjunction with various types of knitting machines or fabric production machines or garment production machines; such as (as non-limiting examples), a circular knitting machine, a tubular knitting machine, a non-circular knitting machine, a non-tubular knitting machine, a seamless knitting machine, a non-seamless knitting machine, a Cut & Sew (C&S) knitting machine, a single-yarn knitting machine, a multiple-yarn or multi-yarn knitting machine, a single-thread knitting machine, a multiple-thread or multi-thread knitting machine, a weft knitting machine, a warp knitting machine, a straight bar knitting machine, a flat bar knitting machine, a raschel knitting machine, a tricot knitting machine, a single jersey knitting machine, a single jersey circular knitting machine (e.g., capable of knitting plan single jersey and/or 2-track and/or 4-track and/or Terry and/or fleece and/or jacquards), a double jersey knitting machine, a double jersey circular knitting machine (e.g., capable of knitting rib and/or pique and/or interlock), a flat bed knitting machine, a V-bed knitting machine, a needle-by-needle knitting machine, a knitting machine having a plurality of needles that can be individually controlled and/or actuated via a controller or processor or knitting program or logic gate (e.g., able to provide to each needle a command of “stitch” or “skip”, or a command of “stitch” or “miss”, or other types of knitting-related commands), and/or other suitable machines.
Reference is made to FIG. 11A, which is a schematic illustration of a sock 1101, in accordance with some demonstrative embodiments. The lines that are shown in thicker ink, indicate the unravel free/roll-free edges or openings or garment-regions.
In FIG. 11A, reference sign “KK” indicate clean-cut edges or zones or unravel-free or roll-free zones or garment-portions or garment-regions, located at or the opening of the sock or the Cuff of the sock. The Special Yarn may be knitted or fused or otherwise placed in or at or near the garment-region marked with “KK”, or in or at or near the sock opening or the sock's Cuff region, or may be parallel and circular to the circular opening of the sock; or may be within N millimeters of the edge or the opening of the sock (e.g., wherein N is, for example, 0 or 1 or 2 or 3 or 4 or 5 or 7 or 10 millimeters; or, wherein N is a number in the range of 0 to 5 millimeters; or, wherein N is a number in the range of 0 to 10 millimeters; or the like), or near or at the edge of the sock near that reference sign; and such Special Yarn is fused or melted or heat-pressed or heat-treated or pressure-and-heat treated, in order to achieve and/or improve the unravel-free/roll-free characteristic of that garment-region of the sock.
Reference is made to FIG. 11B, which is a schematic illustration of an open-toe sock 1102 (or, a toe-less sock; or a sock that lacks a toe pocket; or a sock that lacks a toes pocket), in accordance with some demonstrative embodiments. The lines that are shown in thicker ink, indicate the unravel free/roll-free edges or openings or garment-regions.
In FIG. 11B, reference sign “KK” indicates clean-cut edges or zones or unravel-free or roll-free zones or garment-portions or garment-regions, located at or the top-side opening of the sock or the Cuff of the sock. The Special Yarn may be knitted or fused or otherwise placed in or at or near the garment-region marked with “KK”, or in or at or near the sock's top-side opening or the sock's Cuff region, or may be parallel and circular to the top-side circular opening of the sock; or may be within N millimeters of the edge or the top-side opening of the sock (e.g., wherein N is, for example, 0 or 1 or 2 or 3 or 4 or 5 or 7 or 10 millimeters; or, wherein N is a number in the range of 0 to 5 millimeters; or, wherein N is a number in the range of 0 to 10 millimeters; or the like), or near or at the edge of the sock near that reference sign; and such Special Yarn is fused or melted or heat-pressed or heat-treated or pressure-and-heat treated, in order to achieve and/or improve the unravel-free/roll-free characteristics of that garment-region of the sock.
Additionally, in FIG. 11B, reference sign “LL” indicates clean-cut edges or zones or unravel-free or roll-free zones or garment-portions or garment-regions, located at or the bottom-side (or lower-side) opening of the sock (e.g., located near the base of the toes; or, located near the place in which a toe pocket would commence). The Special Yarn may be knitted or fused or otherwise placed in or at or near the garment-region marked with “LL”, or in or at or near the sock's lower-side (or toes-side) opening, or may be parallel and circular to the lower-side circular opening of the sock; or may be within N millimeters of the edge or the lower-side opening of the sock (e.g., wherein N is, for example, 0 or 1 or 2 or 3 or 4 or 5 or 7 or 10 millimeters; or, wherein N is a number in the range of 0 to 5 millimeters; or, wherein N is a number in the range of 0 to 10 millimeters; or the like), or near or at the edge of the sock near that reference sign; and such Special Yarn is fused or melted or heat-pressed or heat-treated or pressure-and-heat treated, in order to achieve and/or improve the unravel-free/roll-free characteristic of that garment-region of the sock.
It is noted that in the garments that are demonstrated in FIG. 11A and/or FIG. 11B, as well as in other garments demonstrated above and/or herein, the Special Yarn and/or the edge of the garment and/or the nearby opening of the garment need not necessarily be a straight line; but rather, it may be curved, or concave, or convex, or may be structured to have a wave pattern, or may be structured to have a zigzag pattern, or may be diagonal or slanted, or may have other suitable structure; not merely for ornamental purposes, but rather, in order to improve or enhance (in some implementations) the unravel-free and/or the roll-free properties of that garment or garment-region or of the nearby garment-opening or garment-edge.
In some embodiments, the utilization or the incorporation or the embedding of the Special Yarn, at the edge or near the edge, or in proximity to the edge, or at the opening or near the opening, or in proximity to the opening, of a garment or a garment-region, may further provide enhanced Grip capability or Gripping function or body-griping capability to that garment or garment region; in addition to, or instead of, providing unravel-free capability and/or providing roll-free capability and/or reducing raveling and/or reducing rolling of that garment's edge or opening.
The Applicants have realized that there is a challenge in the textile garments industry, to ensure that the garment (or a particular garment-region) would stay in place and/or would not move along the body of the human wearer; particularly as time progresses since the garment was put on, and/or particularly when the wearer engages in running or jogging or exercising or walking or standing or bending or standing-up or sitting-down or other physical movements.
For example, realized the Applicants, when wearing High-Waist Boxers or High-Waist Briefs or similar underwear, or High-Waist leggings or pants or tights or yoga pants or activewear, such garments (or undergarments) may tend to slide down, especially when (or in response to) seating or bending. Similarly, a bra or a sports bra (or a region thereof) may move along the wearer's body or may change its position or location on the wearer's body, during a sports activity; whereas many women wearer would prefer that the bra or sports bra would continue to remain at the same body region (e.g., to prevent or reducing bouncing of the chest, or to provide continuous and uniform support to the breast). Similarly, a wearer of a T-Shirt may prefer that the shirt's waistband or waist-region would remain at or near the waist, and would not raise upwardly (e.g., during running or jogging or sports activity). Similarly, a sock (with a toe pocket, or without a toe pocket) may similarly shift its position during the day and/or in response to physical activity of the wearer; for example, the Cuff area at the upper-side opening of the sock may gradually shift or move or slide downwardly. Similarly, an front-side edge or opening, of a sock that lacks a toe pocket, may start moving upwardly or backwardly (e.g., towards the heel) during the day and/or in response to physical activity; in contrast with the wearer's desire that this garment-region would remain in place relative to the foot.
In accordance with some embodiments, a Grip or Enhanced Grip functionality or capability or effect, are provided to the garment or garment-region or the “cut free” zone or the unravel-free zone or the roll-free zone; due to the utilization and knitting with the Special Yarn in that zone or region. The Special Yarn may be, or may comprise, X4zol™-J as described above, or other or similar yarn(s) or thermoplastic yarn(s) as described above. In some embodiments, a higher or a high thread count of the Special Yarn may be used, to enhance or improve the Grip capability that is obtained by the fusing or melting or heating or hardening of the Special Yarn. In some embodiments, the enhanced Grip capability may be achieved by incorporating the X4zol™-J yarn or the Special Yarn, without performing any fusing or heating or melting or chemical hardening thereof, by utilizing a particular or pre-defined thread-count or yarn-count to achieve the suitable or desired gripping force; for example, with a count of 20 Denier, or 40 Denier, or 70 Denier, or 140 Denier, or 210 Denier, or 360 Denier, or other suitable count. In some embodiments, optionally, the Grip functionality may be achieved or enhanced by knitting with other types of Special Yarn or other yarns; for example, using Silicon yarn or Silicone yarn (e.g., formed of 100% Silicon or Silicone), having a linear density of (for example) 100 or 130 or 150 or 180 or 200 or 220 or 250 dtext (or decitex); or a yarn formed of (or containing) between 40 to 50 percent of Silicone, or formed of (or containing) 43 or 44 or 44.5 or 45 or 46 or 47 percent of Silicone (e.g., having linear density of 120 or 130 or 150 dtex) and the remainder being Nylon; and such Silicone-based yarn may optionally be used without any fusing or heating or melting, to provide the enhanced Grip capability.
In some embodiments, the Grip properties may be achieved or enhanced, by using one or more knitting techniques, or by mixing two or more knitting techniques; for example: Single Jersey, laid in 1×1, laid in 2×1, laid in 3×1, laid in 4×1, laid in 1×2, laid in 1×3, laid in 1×4, Miss 1×1, Miss 2×1, Miss 3×1, Miss 4×1, Miss 1×2, Miss 1×3, Miss 1×4, Tack 1×1, Tack 2×1, Tack 3×1, Tack 4×1, Tack 1×2, Tack 1×3, Tack 1×4, Mesh 1×1, Mesh 2×1, Mesh 3×1, Mesh 4×1, Mesh 1×2, Mesh 1×3, Mesh 1×4, or the like, or a combination of two or more of the above.
In a demonstrative embodiment, a waist-area or waist-band or waist-region of a garment may be produced to have improved Body Grip capabilities; for example, by knitting (for example) the Special Yarn all around the waistband in a knitting structure of laid-in 3×1 (namely, 3 needles laid-in, and 1 needle Miss); and as a result, providing and exposing 75% of the Special Yarn all around and all over the waist band, with a high thread-count or filament count (e.g., 300 or 330 or 360 or 380 Denier).
In some embodiments, the Special Yarn may be, or may comprise, Nylon 6 and/or Nylon 66.
The term “Nylon 66”, as used herein, may include material(s) known also as Nylon 6-6, Nylon 6/6, Nylon 6,6, Nylon 6:6, Nylon 6,6, or Nylon 6.6; it is a type of polyamide or Nylon; it is made of two monomers, each monomer containing 6 carbon atoms, hexamethylenediamine and adipic acid; it is also known as Poly[imino(1,6-dioxohexamethylene) iminohexamethylene], or as Poly(azanediyladipoylazanediylhexane-1,6-diyl).
The term “Nylon 6” as used herein may include polycaprolactam, or a particular polymer which is a semi-crystalline polyamide; unlike many other nylons, Nylon 6 is not a condensation polymer, but rather is formed by ring-opening polymerization; also known as Poly(azepan-2-one); poly(hexano-6-lactam), or Poly[azanediyl(1-oxohexane-1,6-diyl)].
In some embodiments, the knitting structure for improving Grip may be, for example: All the Odd feeds of the knitting machine (e.g., feeds number 1, 3, 5, 7) are knitted with Nylon Drawn Textured Yarn (also known as Nylon DTY, or as DTY Nylon), such as Nylon 6 Nylon 66, or Nylon 6 DTY, or Nylon 66 DTY, with properties of 22/40/2 dtex, plated with Regular Spandex (e.g., 78 dtex) (or Lycra, or Elastane; it is polyether-polyurea copolymer, or a long-chain synthetic polymeric fiber; having soft and rubbery segments of polyester or polyether polyols which allow the fiber to stretch up to 600% and then recover to its original shape, and also having hard segments, formed of urethanes or urethane-ureas, which provide rigidity and/or impart tensile strength and limit plastic flow) in plain knitting; while all the Even feeds of the knitting machine (e.g., feeds number 2, 4, 6, 8) are knit only with the Special Yarn described above (e.g., at 300 or 330 or 360 or 380 Denier) in laid-in structure (e.g., laid in 3×1).
In some embodiments, a single garment may have two (or more) different garment-regions having two (or more) different levels of Grip capability; for example, achieved by utilizing two or more different knitting structures and/or two or more different materials (or ratios of materials) and/or two or more different knitting structures (e.g., laid-in or Mesh or Tack or Miss) and/or two or more different knitting patterns (e.g., straight line, curved line, zigzag, wave; straight line that is parallel to the garment edge; straight line that is perpendicular to the garment edge; straight line that is diagonal or is slanted at a particular angle relative to the garment edge). For example, a first “Grip zone” may be located at or near a neck opening, or the edge (or opening) of the sleeve of a short-sleeve shirt, and may provide a first level of grip; a second “Grip zone” may be located at or near a neck opening, or the edge (or opening) of the neck of the shirt, and may provide a second, different, level of grip; and optionally, a third “Grip zone” may be located at or near (or around) a waist area of the shirt, and may provide a third, different, level of grip; and optionally,
For example, increased Grip capability may be provided a waist region of a garment, by knitting the Side portions of the waist region or waistband: All the Odd feeds (e.g., feeds 1, 3, 5, 7) are knit with DTY Nylon (6.6) 22/40/2 dtex plated with Regular Spandex (e.g., 78 dtex) in plain knitting; and all the Even feeds (e.g., feeds 2, 4, 6, 8) are knit only with the Special Yarn (e.g., at 300 or 330 or 360 or 380 Denier) with laid in structure (for example, laid in 3×1). Additionally, the remainder (non-side; such as, front and rear) of the waistband may be knitted as follows: All the Odd feeds (e.g., feeds 1, 3, 5, 7) are knit with DTY Nylon (6.6) 22/40/2 dtex plated with Regular Spandex (e.g., 78 dtex) in plain knitting; and all the Even feeds (e.g., feeds 2, 4, 6, 8) are knit only with the Special Yarn (e.g., at 300 or 330 or 360 or 380 Denier) with a different laid in structure (for example, laid in 1×1).
In some embodiments, the Grip capability may be configured during the production process by using, or avoiding to use, or by fine-tuning, the fusing or melting or heating operations that (if applied) cause the Special Yarn to harden or to become more rigid or to provide more body support or body grip; or by performing heat press, and/or ironing, and/or boarding, and/or heating the knitted fabric (or the knitted garment region) while also pressing it, and/or by causing the Special Yarn (or at least portions thereof) to melt and/or to fuse with surrounding yarn(s); and/or by configuring or increasing or decreasing or modifying the temperature of the heating (e.g., to achieve more fusing or less fusing, or to reduce or to increase the percentage of Special Yarn that melts and/or fuses); and/or by configuring or increasing or decreasing or modifying the time-length or time-durations or the number of time-intervals of the heating operations (e.g., to achieve more fusing or less fusing, or to reduce or to increase the percentage of Special Yarn that melts and/or fuses); configuring or increasing or decreasing or modifying the pressure (e.g., in Bars) of the pressing or heat-pressing operations (e.g., to achieve more fusing or less fusing, or to reduce or to increase the percentage of Special Yarn that melts and/or fuses).
Functions, operations, components and/or features described herein with reference to one or more embodiments, may be combined with, or may be utilized in combination with, one or more other functions, operations, components and/or features described herein with reference to one or more other embodiments, or vice versa.
While certain features of some embodiments have been illustrated and described herein, many modifications, substitutions, changes, and equivalents may occur to those skilled in the art. Accordingly, the claims are intended to cover all such modifications, substitutions, changes, and equivalents.

Claims

What is claimed is:

1. A garment comprising:

a particular garment-region made of knitted fabric,

wherein a majority of threads of said knitted fabric in said particular garment-region are yarns other than a thermally-fused thermoplastic yarn, wherein said yarns are one or more yarns selected from the group consisting of: cotton, polyester, nylon, polypropylene, cellulose, polyurethane;

wherein at least one thread of said knitted fabric in said particular garment-region is a thermally-fused thermoplastic yarn that is knitted integrally in said knitted fabric and is located within N millimeters from an edge or an opening of said garment, wherein N is in the range of 0 to 10 millimeters,

wherein the edge or the opening of said particular garment-region is unravel free and is roll-free due to inclusion of or proximity to said thermally-fused thermoplastic yarn in said knitted fabric in said particular garment-region.

2. The garment of claim 1,

wherein the garment is a garment selected from the group consisting of: pants, leggings, tights, sports pants, yoga pants, shorts, boxers, underwear;

wherein said particular garment-region is bordering a leg opening of said garment;

wherein at least one thread of said knitted fabric in said particular garment-region is a thermally-fused thermoplastic yarn that is knitted integrally in said knitted fabric and is located within N millimeters from an edge of said leg opening, wherein N is in the range of 0 to 10 millimeters.

3. The garment of claim 1,

wherein said particular garment-region is bordering a waist-band of said garment;

wherein at least one thread of said knitted fabric in said particular garment-region is a thermally-fused thermoplastic yarn that is knitted integrally in said knitted fabric and is located within N millimeters from an edge of said waist-band, wherein N is in the range of 0 to 10 millimeters.

4. The garment of claim 1,

wherein the garment is a garment selected from the group consisting of: short-sleeve shirt, long-sleeve shirt, semi-long sleeve shirt, sleeveless shirt, tank top;

wherein said particular garment-region is bordering an arm opening of said garment;

wherein at least one thread of said knitted fabric in said particular garment-region is a thermally-fused thermoplastic yarn that is knitted integrally in said knitted fabric and is located within N millimeters from an edge of said arm opening, wherein N is in the range of 0 to 10 millimeters.

5. The garment of claim 1,

wherein said particular garment-region is bordering a neck opening opening of said garment;

wherein at least one thread of said knitted fabric in said particular garment-region is a thermally-fused thermoplastic yarn that is knitted integrally in said knitted fabric and is located within N millimeters from an edge of said neck opening, wherein N is in the range of 0 to 10 millimeters.

6. The garment of claim 1,

wherein the garment is a garment selected from the group consisting of: bra, brassiere, sports bra;

wherein said particular garment-region is a shoulder strap of said garment;

wherein at least one thread of said knitted fabric in said particular garment-region is a thermally-fused thermoplastic yarn that is knitted integrally in said knitted fabric and is located within N millimeters from an edge of said shoulder strap, wherein N is in the range of 0 to 10 millimeters.

7. The garment of claim 1,

wherein said particular garment-region comprises a front band located under the breast cups of said garment;

wherein at least one thread of said knitted fabric in said particular garment-region is a thermally-fused thermoplastic yarn that is knitted integrally in said knitted fabric and is located within N millimeters from an edge of said front band, wherein N is in the range of 0 to 10 millimeters.

8. The garment of claim 1,

wherein said particular garment-region is a tubular portion of said garment, and comprises two folded, symmetrical, heat-and-pressure treated, layers of knitted tubular fabric that comprise said thermally-fused thermoplastic yarn that is knitted integrally therein.

9. The garment of claim 1,

wherein said thermally-fused thermoplastic yarn that is integrally knitted in said fabric of said particular garment-region and is parallel to an edge of said particular garment-region.

10. The garment of claim 1,

wherein said thermally-fused thermoplastic yarn that is integrally knitted in said fabric of said particular garment-region and is perpendicular to an edge of said particular garment-region.

11. The garment of claim 1,

wherein said thermally-fused thermoplastic yarn that is integrally knitted in said fabric of said particular garment-region and is slanted at an angle in a range of 1 to 89 degrees relative to an edge of said particular garment-region.

12. The garment of claim 1,

wherein said thermally-fused thermoplastic yarn is a set of at least two, spaced-apart, thermally-fused thermoplastic yarns that are parallel to each other and that are integrally knitted in said fabric of said particular garment-region and are parallel to an edge of said particular garment-region.

13. The garment of claim 1,

wherein said thermally-fused thermoplastic yarn is a set of at least two, spaced-apart, thermally-fused thermoplastic yarns that are parallel to each other and that are integrally knitted in said fabric of said particular garment-region and are perpendicular to an edge of said particular garment-region.

14. The garment of claim 1,

wherein said thermally-fused thermoplastic yarn is a set of at least two, spaced-apart, thermally-fused thermoplastic yarns that are parallel to each other and that are integrally knitted in said fabric of said particular garment-region and are slanted at an angle in a range of 1 to 89 degrees relative to an edge of said particular garment-region.

15. The garment of claim 1,

wherein said thermally-fused thermoplastic yarn is a set of at least two, spaced-apart, thermally-fused thermoplastic yarns that are parallel to each other and that are integrally knitted in crisscross structure in said fabric of said particular garment-region within N millimeters from an edge of said particular garment-region, wherein N is in the range of 0 to 10 millimeters.

16. The garment of claim 1,

wherein said thermally-fused thermoplastic yarn is a set of at least two, spaced-apart, curved, non-straight, thermally-fused thermoplastic yarns that are parallel to each other and that are integrally knitted in a structure of curved parallel lines in said fabric of said particular garment-region within N millimeters from an edge of said particular garment-region, wherein N is in the range of 0 to 10 millimeters.

17. The garment of claim 1,

wherein said thermally-fused thermoplastic yarn that is integrally knitted in said fabric of said particular garment-region is touching only a portion, and not all, of the edge of said particular garment-region.

18. The garment of claim 1,

wherein said thermally-fused thermoplastic yarn that is integrally knitted in said fabric of said particular garment-region is touching an entirety of the edge of said particular garment-region.

19. The garment of claim 1,

wherein said thermally-fused thermoplastic yarn is a thermally-fused thermoplastic yarn formed from monofilament melt spun fibers which are pressure-and-heat stamped and which have fiber thickness in a range of 20 denier to 400 denier.

20. The garment of claim 1,

wherein said thermally-fused thermoplastic yarn is a thermally-fused thermoplastic yarn formed from monofilament melt spun fibers which are pressure-and-heat stamped and which have fiber thickness in a range of 20 denier to 100 denier.

21. The garment of claim 1,

wherein said thermally-fused thermoplastic yarn is integrally knitted into said knitted fabric in a structure selected from the group consisting of: single jersey structure, miss knitting structure, tack knitting structure, mesh knitting structure, a combination of two or more of said structures.

22. The garment of claim 1,

wherein an edge of said particular garment-region is a finished seamless edge that is non-unraveling and is roll-free.

23. The garment of claim 1,

wherein said thermally-fused thermoplastic yarn is a melt spun thermoplastic polyurethane polymer monofilament comprising a crosslinking agent and having a modulus of 300% in a range of 1,571 psi to 1,861 psi.

24. The garment of claim 1,

wherein said thermally-fused thermoplastic yarn is a melt spun lightly-crosslinked thermoplastic polyurethane polymer monofilament having a modulus of 300% in a range of 1,550 psi to 1,880 psi;

wherein said lightly-crosslinked thermoplastic polyurethane polymer monofilament comprises a crosslinking agent of 8% to 15% by weight of a final weight of said thermally-fused thermoplastic yarn.

25. The garment of claim 1,

wherein said thermally-fused thermoplastic yarn is a melt spun TPU monofilament fiber having a thickness in a range of 20 denier to 400 denier; wherein said fiber comprises a reaction product of: (A) a blend of at least two polyether hydroxyl terminated intermediates, wherein said polyether hydroxyl terminated intermediates have different Number Value Molecular Weight (Mn) values; (B) at least one chain extender; (C) at least one polyisocyanate; and (D) at least one crosslinking agent;

wherein said TPU in said monofilament fiber has a 300% modulus of from 1,500 to 1,900 psi, and a maximum elongation of from 550% to 680%, and a tenacity of from 5,000 to 5,700 psi.

26. The garment of claim 1,

wherein said thermally-fused thermoplastic yarn provides to said particular garment-region an improved body grip capability, relative to body grip capability of other garment-regions of said garment that exclude said thermally-fused thermoplastic yarn;

wherein said thermally-fused thermoplastic yarn provides to said particular garment-region an improved non-unraveling capability, relative to non-unraveling capability of other garment-regions of said garment that exclude said thermally-fused thermoplastic yarn;

wherein said thermally-fused thermoplastic yarn provides to said particular garment-region an improved roll-free capability, relative to roll-free capability of other garment-regions of said garment that exclude said thermally-fused thermoplastic yarn.

27. A method for producing a garment, the method comprising:

(a) knitting a particular garment-region from yarns,

wherein at least one thread of said knitted fabric in said particular garment-region is a thermally-fused thermoplastic yarn that is knitted integrally in said knitted fabric and is located within N millimeters from an edge or an opening of said garment, wherein N is in the range of 0 to 10 millimeters;

(b) applying a heat-and-pressure treatment to said particular garment-region, for a pre-defined time-period,

and causing said thermally-fused thermoplastic yarn to at least partially melt and change its physical properties of elongation, elasticity and/or tenacity due to said heat-and-pressure treatment,

and causing an edge or an opening of said particular garment-region to become unravel free and roll-free due to inclusion of or proximity to said thermally-fused thermoplastic yarn in said knitted fabric in said particular garment-region that was subject to said heat-and-pressure treatment.

28. A process for producing a garment, the process comprising:

(a) producing a particular garment-region having a seamless finished edge that is roll-free and unravel-free;

wherein step (a) is performed by:

(a1) knitting a fabric having a plurality of fibers, wherein at least some of said fibers have free ends terminating at an edge of said fabric;

(a2) disposing a melt spun thermoplastic polyurethane polymer monofilament over the edge of said fabric, wherein said melt spun thermoplastic polyurethane polymer monofilament engages with said free ends of said fibers at the edge of said fabric;

(a3) applying a heat-and-pressure treatment to said melt spun thermoplastic polyurethane polymer monofilament for a pre-defined time period,

wherein said melt spun thermoplastic polyurethane polymer monofilament comprises a crosslinking agent in a range of 8% to 15% by weight of a final weight of said melt spun thermoplastic polyurethane polymer monofilament;

wherein said melt spun thermoplastic polyurethane polymer monofilament has a 300% modulus of from 1,500 to 1,900 psi.