U.S. patent application number 10/962861 was filed with the patent office on 2005-05-26 for performance sports garments formed from single layer double-faced performance warp knit fabric and method of making same.
Invention is credited to Kevin, Plank, McMurray, Brian.
Application Number | 20050112976 10/962861 |
Document ID | / |
Family ID | 34591689 |
Filed Date | 2005-05-26 |
United States Patent
Application |
20050112976 |
Kind Code |
A1 |
McMurray, Brian ; et
al. |
May 26, 2005 |
Performance sports garments formed from single layer double-faced
performance warp knit fabric and method of making same
Abstract
Performance sports garments formed containing an integrally
formed stretch warp knit fabric structure formed from a single
layer fabric having definitive two-sided qualities. 1373-008
Inventors: |
McMurray, Brian; (Pinehurst,
NC) ; Kevin, Plank; (Baltimore, MD) |
Correspondence
Address: |
JINAN GLASGOW
300 N. GREENE ST., SUITE 1600
P.O. BOX 2974
GREENSBORO
NC
27401
US
|
Family ID: |
34591689 |
Appl. No.: |
10/962861 |
Filed: |
October 12, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10962861 |
Oct 12, 2004 |
|
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10720947 |
Nov 24, 2003 |
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Current U.S.
Class: |
442/306 ;
442/308; 66/202 |
Current CPC
Class: |
D10B 2401/021 20130101;
Y10T 442/2066 20150401; D04B 21/18 20130101; Y10T 442/2098
20150401; D10B 2403/0114 20130101; D10B 2401/022 20130101; D10B
2501/02 20130101; Y10T 442/2762 20150401; Y10T 442/20 20150401;
Y10T 442/45 20150401; D10B 2403/0111 20130101; Y10T 442/413
20150401; Y10T 428/2395 20150401; Y10T 442/463 20150401; D04B 21/04
20130101; Y10T 442/2861 20150401; Y10T 442/425 20150401; Y10T
442/456 20150401 |
Class at
Publication: |
442/306 ;
442/308; 066/202 |
International
Class: |
D04B 007/16; D04B
021/12; D04B 011/12; D04B 001/18 |
Claims
What is claimed is:
1. A performance garment using a multi-directional stretch
performance fabric comprising: A two-sided single layer stretch
warp knit fabric further comprising a first side and a second side
that are integrally formed during knitting wherein each side has at
least one different quality from the other side, wherein the
two-sided single layer stretch warp knit fabric is processed to
form a performance garment having an inside and outside
corresponding to the first side and the second side of the fabric,
respectively.
2. The performance garment of claim 1, wherein the processing
includes cutting into components, configuring, and attaching the
components to form the performance wear garment, utilizing a
two-sided single layer warp knit as a main component and may be in
combination with other warp knit or weft knit fabrics, according to
the garment design.
3. The garment of claim 1, wherein the performance garment is used
in applications including sports, and fitness activities, as well
as everyday leisure wear, casual wear, or generally non-sporting,
non-physically exertive attire.
4. The garment of claim 1, wherein the fabric includes a spandex
yarn component.
5. A method for forming a garment comprising the steps of:
providing a two-sided single layer stretch warp knit fabric
comprising a first side and a second side that are integrally
formed, such that the first and second sides of the fabric have at
least one different quality from the other side, cutting the fabric
into garment components using a pattern; attaching predetermined
components to form the garment by either conventional sewing
technology, ultrasonic welding, adhesive seaming, or any such
method of fabricating a garment by joining them at seams, wherein
the garment has an inside and an outside corresponding to the first
and second sides of the fabric, respectively such that the inside
and the outside of the garment having at least one different
quality from each other.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This nonprovisional utility patent application claims the
benefit of one or more prior filed copending nonprovisional
applications; a reference to each such prior application is
identified as the relationship of the applications and application
number (series code/serial number): The present application is a
Continuation-In-Part of application 10/720,947, which is
incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] (1) Field of the Invention
[0003] The present invention relates generally to textile fabrics
and, more particularly, to a double-faced warp knit fabric for
performance garment applications.
[0004] (2) Description of the Prior Art
[0005] Prior art includes reversible garments having different
inside and outside parts of the garment, typically provided by two
fabrics joined together at seams, i.e., woven or knitted fabrics
that are later joined together, wherein the two fabrics have a
differing qualities, such as color, design or pattern, or texture.
Examples include: U.S. Pat. No. 6,647,551 issued Nov. 18, 2003 to
Palumbo for Reversible garment; U.S. Pat. No. 5,561,860 issued Oct.
08, 1996 to Nguyen-Senderwicz for Reversible two-toned and/or
two-textured shirt/sweater with extended sleeves; U.S. Pat. No.
5,204,995 issued Apr. 27, 1993 to Knapp for Fashionable reversible
pants; U.S. Pat. No. 4,310,929 issued Jan. 19, 1982 to Finlay for
Reversible running shorts; U.S. Pat. No. 4,296,498 issued Oct. 27
1981 to Vinson for Reversible garment; U.S. Pat. No. 4,414,691
issued Nov. 15, 1983 to Estruch for Reversible bathing garment;
U.S. Pat. No. 6,128,783 issued Oct. 10, 2000 to Blauer, et al. for
Reversible sweater with opposing sides that optionally present
either customary appearance or enhanced visibility; U.S. Pat. No.
4,481,683 issued Nov. 13, 1984 to Estruch for Reversible uni-sex
garment;
[0006] Notably, typically the prior art reversible garments are
characterized by their two distinct fabrics, one forming an inside
and the other forming the outside, which are intended to be
reversed inside/outside for different effect.
[0007] In another form of prior art, U.S. patent application Ser.
No. 20040048540 published Mar. 11, 2004 for inventor Dailly for
Fabric for garment and resulting garment provides a two-sided knit
fabric having two layers that are assembled closely together by a
knitting process with incorporation of an elastic thread. In
particular, the fabric combines sweat- repellent and thermally
insulating characteristics via these superposed layers including
hollow synthetic fibers.
[0008] Thus, there remains a need for a garment formed from a
single layer double-faced warp knit fabric having different
qualities on the face and back sides, and wherein the garment is
formed from a single fabric.
SUMMARY OF THE INVENTION
[0009] The present invention provides garment embodiments utilizing
single layer double-faced warp knit fabrics having different
qualities on the face and back sides of the fabric that correspond
to different inside and outside surfaces of the garment, wherein
the sides are aesthetically enhanced fabrics with advantageous
performance properties. The garment embodiments may also include
other suitable and appropriate warp knit or weft knit fabrics in
combination with the said single layer double-faced warp knit of
the present invention in any proportion according to the garment
design. The present invention also provides methods for producing
such fabrics.
[0010] In an aspect the present invention a garment formed from a
single layer fabric having a definitive two-sided, and even more
desirably, two distinctive and different colors on each side as a
result.
[0011] More specifically an embodiment of the present invention
provides a garment having a definitive two-sided single layer warp
knit fabric structure with a first technical back side forming the
inside of the garment including a textured micro-denier
multifilament synthetic yarn such as nylon or polyester, preferably
polyester, and a base structure comprised of spandex elastomeric
yarn, and a second technical face side forming the outside of the
garment including a fully dyeable synthetic either continuous
multifilament or a spun staple length yarn such as nylon or
polyester, preferably nylon, and a second technical back side
forming the inside of the garment including a textured micro-denier
multifilament synthetic yarn such as nylon or polyester, preferably
polyester, and a base structure comprised of spandex elastomeric
yarn.
[0012] Any of the conventional yarn types known in the art may be
utilized to produce a warp knit fabric for use with the performance
garments of the present invention, including, but not limited to
natural and synthetic yarns produced from spandex, nylon,
polyester, viscose, cotton and/or blends thereof. In a preferred
embodiment of the present invention the technical back-side of the
single layer warp knit fabric is comprised of a substantially
resilient and thermo-settable continuous filament synthetic yarn.
The synthetic yarn may comprise a textured multifilament yarn, a
flat non-textured multifilament yarn, or a spun staple yarn wherein
the synthetic yarn comprises polyester or nylon. In the case of a
flat non-textured multifilament yarn, a higher reflectance surface
can be produced thereby imparting a metallic look effect,
particularly when the yarn is either solution dyed, yarn dyed, or
fabric piece dyed in the into silver or gold metallic looking
colors.
[0013] A particularly desirable combination is achieved when any
fashionable color such as Navy or Red, for example, is dyed only on
the yarn visible in the technical face side of the fabric, which
corresponds to the outside of the garment, while a contrasting and
different color such as silver is dyed on the yarn visible on the
technical back side of the fabric, which corresponds to the inside
of the garment, resulting in a silver backed fabric having any
color on the reverse face of the garment product. The garment may
also include other types of warp knit or weft knit fabric
constructions that enhance the garment in function and/or
aesthetics.
[0014] A feature of the present invention is that an embodiment of
the present invention provides a garment formed from a single layer
double faced or distinctly two-sided warp knit fabric wherein the
first and second distinct and different yarn layers together in a
tightly spaced relationship parallel to each other.
[0015] Another feature of the present invention is that an
embodiment of the present invention provides a multi-directional
stretch performance fabric utilizing synthetic polymer spandex
elastomeric yarn.
[0016] A further feature of the present invention is that a
performance sports garment embodiment of the present invention
provides for a sueded or brushed technical back fabric surface,
corresponding to the inside of the garment, for maximizing wearer
comfort.
[0017] Embodiments of the present invention provide methods of
making performance garments using single layer warp knitted double
faced fabrics that may have a luster range from a full dull luster
face, any intermediate luster such as semi-dull or semi-bright, or
a bright or high luster face, a Printed face, Embossed face, or
Specialty Yarn faced fabric consisting of a first distinct and
opaque outer technical face fabric surface, a second distinct inner
technical back fabric surface that may be either fully dull or
highly bright in luster, and that will facilitate the manufacturing
of performance sports garments in a minimal number of manufacturing
steps.
[0018] These and other aspects of the present invention will become
apparent to those skilled in the art after a reading of the
following description of the preferred embodiment when considered
with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a front view of a sleeveless garment constructed
according to the present invention.
[0020] FIG. 2 is a front view of an alternative, short-sleeved
garment constructed according to the present invention.
[0021] FIG. 3 is a front view of another alternative, long-sleeved
garment constructed according to the present invention.
[0022] FIG. 4 shows a front view of yet another alternative garment
constructed according to the present invention.
[0023] FIG. 5 shows a front view of another alternative garment
according to the present invention.
[0024] FIG. 6 illustrates a front view of another alternative
garment according to the present invention.
[0025] FIG. 7 illustrates a front view of another alternative
garment according to the present invention.
[0026] FIG. 8 shows a front view of another alternative garment
according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] In the following description, like reference characters
designate like or corresponding parts throughout the several views.
Also in the following description, it is to be understood that such
terms as "forward," "rearward," "front," "back," "right," "left,"
"upwardly," "downwardly," and the like are words of convenience and
are not to be construed as limiting terms.
[0028] Referring now to the drawings in general, the illustrations
are for the purpose of describing preferred embodiments of the
invention and are not intended to limit the invention thereto. The
various FIGS. 1-8 all show particular embodiments for performance
sports garments according to the present invention, each with some
garment pattern difference, intended to illustrate but not limit
the range of garment types to which the present invention applies.
All of the garments set forth herein are formed using a knitted
fabric according to the prior filed parent application 10/720,947,
of which this application is a Continuation-In-Part, which is
incorporated herein by reference in its entirety regarding the
fabric construction, and may be used in combination with other warp
knit or weft knit fabrications according to each unique garment
design embodiment.
[0029] As seen in FIG. 1, a knitted sleeveless shirt is constructed
according to the present invention is shown. FIG. 1 shows a first
fabric surface 10 and a second fabric surface 12, wherein the first
fabric surface corresponds to the inside of the garment and the
second fabric surface corresponds to the outside of the garment,
when the garment is worn in its intended orientation. Similarly,
all figures show first (10) and second (12) fabric surfaces
corresponding to the inside and outside of the garment,
respectively.
[0030] Similarly, FIGS. 2 and 3 illustrate alternative patterns for
making a knitted shirt constructed according to alternative
embodiments of the present invention. FIG. 2 shows a short-sleeved
shirt embodiment, while FIG. 3 shows a long-sleeved shirt
embodiment.
[0031] FIG. 4 illustrates a knitted pants embodiment, once again
with inside and outsides of the garment indicated. FIGS. 7 and 8
show short knitted pants constructions, including sports
performance underwear in FIG. 7.
[0032] FIGS. 5 and 6 show tank top embodiments, with FIG. 6 having
narrower straps and an alternative construction. Importantly, in
more delicate apparel garments, such as illustrated in FIG. 6 or
even in underwear garments as in FIG. 7, it is not possible to
utilize the reversible garment constructions according to any of
the various prior art, since combining more than one fabric via
seaming or other connection would render the garment too bulky to
be worn as close-fitting, lightweight sports performance
apparel.
[0033] The design examples set forth in the FIGS. 1-8 in the
foregoing description are not necessarily optimized but
illustrative of what can be done for a system and method and
indicative of the preferred embodiment at the time of the
invention.
[0034] The preferred embodiments of the present invention include
garments formed from a two-sided single layer stretch warp knit
fabric having a first (face) side and a second (technical back)
side identified as such for the purposes of the following
description; it will be appreciated that the fabric could be
reversible, in which case the first and second side labeling may be
used to more generally identify and distinguish the fabric's
opposite sides, faces, or surfaces, depending on the application,
design, and function of the fabric.
[0035] The present invention provides for performance garments
formed from a single layer double-faced or distinctly two-sided
warp knit fabric that has first and second knit parallel yarn
layers forming each of a first side and a second side of the fabric
that are integrally knitted and joined together by a series of knit
courses forming a resultant single thickness fabric which
discretely secures the first and second distinct and different yarn
layers together in a tightly spaced relationship parallel to each
other.
[0036] A preferred embodiment of the present invention provides a
sports performance garment that is formed of a warp knitted
single-layer performance fabric that has optimized comfort features
on the inside of the garment, which corresponding to the second
side of the fabric, with at least one different quality on
the,outside of the garment, which corresponds to the first side of
the fabric as illustrated in the various embodiments shown in FIGS.
1-8.
[0037] The outer surface yarn, which is used on the surface of the
second side (12) of the fabric, which corresponds to the outside of
the garment, will also be the visible ingredient in the fabric
therefore will be dyed into fashion colors as desired for the
appropriate end use for performance wear garment applications. The
fabric inner surface backside, which contacts the skin of the
wearer, will thus be hidden from view but provide appropriate
features for the comfort of the garment wearer.
[0038] Thus, the first and second sides of the fabric used for the
garments according to the present invention advantageously provides
for each side having at least one different quality from the other
side, wherein said quality is either quantitatively and/or
qualitatively distinguishable between the first and second sides.
By way of example and not limitation, said at least one different
quality preferably includes color, shade, fiber type(duplicate)
fiber type, pattern, texture, chemical finish, mechanical finish or
additional processing, luster or brightness, opacity, reflectivity,
and/or wherein the side differences affect fabric performance such
as the functional features of wicking, breathability or
permeability, water-resistance, stain resistance, comfort, heat
transfer, insulation or cooling, flame retardant, and combinations
thereof.
[0039] In the case of color differences, the first and second sides
may have different colors or different shades of the same color,
which may be achieved by solution dyeing, yarn dyeing, fabric piece
dyeing, and the like. Additionally or alternatively, the first and
second sides may have differences such as one of the sides having a
metallic color, look or finish, realized by fiber type, finish,
coating, and combinations thereof.
[0040] The first and second sides of the fabric and garment may
have different fiber types in terms of the material or substance
itself, or in terms of the form of the material, such as
multifilament, textured multifilament, spun staple, and the like,
and combinations thereof, which provide for a difference of at
least one quality between the inside and outside of the
garment.
[0041] Another difference between the first (10) and second (12)
sides of the fabric, and subsequently the inner and outer surfaces
of the performance garment in which the fabric is utilized,
according to the present invention, includes the pattern on each
side. Pattern differences include printed, embossed, embroidery,
specialty yarn, and knitting differences on either side; any
variation in pattern from one side to the other that is
distinguishable is considered to fall within the scope of the
present invention, i.e., the difference need not be highly
pronounced, but noticeable by a qualitative and/or quantitative
measure.
[0042] The texture may also vary between the first and second
sides. The two-sided single layer stretch warp knit fabric is
preferably formed using a knitting technique that provides for a
quality unique to each side. The textural differences may be
provided by finish-enhanced means, including but not limited to
brushed, chemically treated, sueded, sanded, and the like, and
combinations thereof, as well as being optionally provided in part
due to the yarn differences, as set forth hereinabove.
[0043] Another difference between the first (10) and second (12)
sides of the fabric and performance garment according to the
present invention is luster and/or brightness or opacity may be one
of the at least one distinguishing quality from the first to second
sides of the two-sided single layer stretch warp knit fabric, which
correspond to inside and outside of the garment formed therewith,
respectively, according to the present invention.
[0044] Another distinction between sides occurs where the side
differences affect fabric performance, i.e., the differences
between the sides produce a functional quality in the fabric
overall, such as stain resistance and wearer comfort, more
specifically the ability of the inner fabric structure inside the
performance garment to efficiently and rapidly move and transport
moisture away from the body of the wearer and transfer it to the
outer garment surface layer by means of a hydrophobic highly
wickable ingredient such as microdenier textured polyester yarn
against the body integrally knitted to and connected with the outer
fabric face of the garment that in turn releases the moisture
through evaporation.
[0045] The present invention provides embodiments such as underwear
garments formed from single layer double-faced warp knit fabrics
having different qualities on the face and back sides that are
aesthetically enhanced fabrics with advantageous performance
properties, such as comfort-enhanced inside properties to benefit
the garment wearer.
[0046] More specifically, one embodiment of the present invention
provides a distinctive inside/outside sports performance garment
formed from a definitive two-sided single layer warp knit fabric
structure with a first technical face side, corresponding to the
garment outside, comprised of a fully dyeable synthetic either
continuous multifilament or a spun staple length yarn such as nylon
or polyester, preferably nylon, and a second technical back side,
corresponding to the garment inside, comprised of a textured
micro-denier multifilament synthetic yarn such as nylon or
polyester, preferably polyester, and a base structure of the fabric
comprised of spandex elastomeric yarn. A range of fabric weights
would be suitable for the garment embodiments according to the
present invention, preferably, between about four to about twelve
oz/yd.sup.2.
[0047] Any of the conventional yarn types known in the art may be
utilized to produce a garment according to the present invention
formed from a warp knit fabric of the present invention, including,
but not limited to natural and synthetic yarns produced from
spandex, nylon, polyester, viscose, cotton and/or blends thereof.
In a preferred embodiment of the present invention a garment is
formed from a two-sided single layer warp knit fabric wherein the
technical back-side of the single layer warp knit fabric is
comprised of a substantially resilient and thermo-settable
continuous filament synthetic yarn. The synthetic yarn may comprise
a textured multifilament yarn, a flat non-textured multifilament
yarn, or a spun staple yarn wherein the synthetic yarn comprises
polyester or nylon. In the case of a flat non-textured
multifilament yarn, a higher reflectance surface can be produced
thereby imparting a metallic look effect, particularly when the
yarn is either solution dyed, yarn dyed, or fabric piece dyed in
the into silver or gold metallic looking colors. A similar look may
be accomplished when using a preferred textured multi-filament
micro-denier polyester yarn which optimizes moisture wicking action
when against and in direct contact with the skin of the garment
wearer.
[0048] Yet another embodiment of the present invention provides a
sports performance garment utilizing a multi-directional stretch
performance fabric. More particularly, in one embodiment, the
multi-directional stretch performance fabric utilizes a synthetic
polymer spandex elastomeric yarn such as Lycra produced by the
DuPont Company of Wilmington, De. The inclusion of spandex yarn
into the fabric structure is integral to the successful execution
of separation of the two distinct yarn systems into technical face
and technical back. Alternatively, a non-spandex stretch yarn, such
as a stretch polyester or extra-stretch polyester, or similar yarn
having stretch properties may be used, depending upon the
application for the fabric, including but not limited to additional
processing steps and/or use of the fabric, including cleaning and
care or fabric maintenance, either alone or in its use as an
article, such as a garment or accessory.
[0049] Another embodiment of the present invention provides for a
sueded or brushed technical back fabric surface for maximizing
wearer comfort and increasing the thermal retention properties of
the fabric and garment.
[0050] Embodiments of the fabric set forth hereinabove may be
advantageously utilized in articles of manufacture. Accordingly,
the present invention includes articles of manufacture comprising a
fabric of the present invention as set forth hereinabove, by way of
example for performance garments of the present invention include a
short sleeved shirt, a long sleeved shirt, a tank top, and the
like.
[0051] The present invention provides a method for forming a
two-sided garment including the steps of: providing a two-sided
single layer stretch warp knit fabric comprising a first side and a
second side that are integrally formed, such that the first and
second sides of the fabric have at least one different quality from
the other side, cutting the fabric into garment components using a
pattern, and attaching predetermined components to form the garment
by sewing them at seams, wherein the garment has an inside and an
outside corresponding to the first and second sides of the fabric,
respectively such that the inside and the outside of the garment
having at least one different quality from each other.
[0052] Methods of making garments using the single layer, warp
knitted, double faced fabrics as set forth hereinabove include
methods for making fabrics that may have a range in texture and
luster from a full dull luster face, any intermediate luster such
as semi-dull or semi bright, to a bright or high luster face, a
printed face, embossed face, or specialty yarn-faced fabric having
a first distinct and opaque outer technical face fabric surface, a
second distinct inner technical back fabric surface that may also
be in a range from fully dull to highly bright in luster, and that
will facilitate the manufacturing of the garments in a minimal
number of manufacturing steps.
[0053] Further steps of processing the fabric to be utilized in the
performance garment may be performed to create at least one
different quality between the first and second sides of the fabric,
such as, by way of example and not limitation: napping, brushing,
sueding, chemical treating, finishing, printing, embossing, and
combinations thereof.
[0054] Certain modifications and improvements will occur to those
skilled in the art upon a reading of the foregoing description. All
modifications and improvements have been deleted herein for the
sake of conciseness and readability but are properly within the
scope of the following claims.
* * * * *