U.S. patent application number 17/051342 was filed with the patent office on 2021-03-11 for modified every course elastified knitted fabrics and garments thereof.
This patent application is currently assigned to The LYCRA Company LLC. The applicant listed for this patent is A&AT LLC. Invention is credited to Alberto CERIA.
Application Number | 20210071327 17/051342 |
Document ID | / |
Family ID | 1000005248887 |
Filed Date | 2021-03-11 |
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United States Patent
Application |
20210071327 |
Kind Code |
A1 |
CERIA; Alberto |
March 11, 2021 |
MODIFIED EVERY COURSE ELASTIFIED KNITTED FABRICS AND GARMENTS
THEREOF
Abstract
Fabrics prepared from a modified every course style with courses
of spandex covered with rigid yarn and bare spandex plated with
rigid yarn and their use in production of fabrics and elastified
knitted garments are provided.
Inventors: |
CERIA; Alberto; (Buccinasco
(MI), IT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
A&AT LLC |
Wilmington |
DE |
US |
|
|
Assignee: |
The LYCRA Company LLC
Wilmington
DE
|
Family ID: |
1000005248887 |
Appl. No.: |
17/051342 |
Filed: |
May 6, 2019 |
PCT Filed: |
May 6, 2019 |
PCT NO: |
PCT/US2019/030824 |
371 Date: |
October 28, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62668013 |
May 7, 2018 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D10B 2501/021 20130101;
D10B 2403/023 20130101; D04B 1/24 20130101; D04B 1/18 20130101 |
International
Class: |
D04B 1/18 20060101
D04B001/18; D04B 1/24 20060101 D04B001/24 |
Claims
1. A fabric prepared from a modified every course style which
comprises courses of spandex covered with rigid yarn and courses of
bare spandex plated with rigid yarn.
2. The fabric of claim 1 knit in a repeating pattern comprising a
course of spandex covered with rigid yarn followed by a course of
bare spandex plated with rigid yarn.
3. The fabric of claim 1 knit in a repeating pattern comprising two
or more courses of spandex covered with rigid yarn followed by a
single course of bare spandex plated with rigid yarn.
4. The fabric of claim 1 knit in a pattern comprising one or more
courses of spandex covered with rigid yarn followed by two or more
courses of bare spandex plated with rigid yarn.
5. The fabric of claim 1 wherein the rigid yarn comprises
polyamide.
6. A garment, a portion of which is prepared from the fabric of
claim 1.
7. A sheer garment, a portion of which is prepared from the fabric
of claim 1.
8. Hosiery, a portion of which is prepared from the fabric of claim
1.
9. A method for improving comfort, increasing gloss, and/or
increasing run resistance of an elastified knitted garment, said
method comprising preparing the garment from the fabric of claim
1.
10. A method for lowering cost of an elastified knitted garment,
said method comprising preparing the garment from the fabric of
claim 1.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to fabrics prepared from a
modified every course style with courses of spandex covered with
rigid yarn and bare spandex plated with rigid yarn and their use in
production of elastified knit garments.
BACKGROUND OF THE INVENTION
[0002] Two traditional choices for incorporating spandex into
garments such as hosiery include every course style as depicted in
FIG. 1A and alternate course style as depicted in FIG. 1B. The
spandex fiber may be covered with, for example, polyamide, or may
be bare, and is knitted in every course as depicted in FIG. 1A or
alternate courses as depicted in FIG. 1B.
[0003] Garments such as every course panty hose (ECPH) comprise
balanced stitches and normally provides for a higher quality
garment. Typically, the spandex is covered. ECPH provides a
balanced smooth appearance and uniform freedom of movement.
However, ECPH can be challenging to knit with yarn quality being
critical, thus making ECPH more costly to produce. Further, ECPH
appears deceptively opaque and undersized before boarding due to
high contraction of the elastane.
[0004] Spandex garments prepared from traditional every course
style such as ECPH are known and produced mainly for their superior
comfort, stretch and uniformity. However, some knitters and
retailers claim not being able to make a "glossy" or "shiny" sheer
garment using a typical ECPH structure with covered yarns due to
the twists of the polyamide eliminating most of its shine.
[0005] Negative aspects including, but not limited to, touch,
fragility and cheap appearance make a sheer, light weight ECPH
prepared via a bare knitting technique without a covered yarn
component undesirable.
[0006] Accordingly, when a shiny hosiery garment is desired, the
shine effect is typically given by the use of a bright polyamide in
alternate course (AC) construction. Most of the shine comes from
the non-elastified course. Garments such as alternate course panty
hose (ACPH) comprise alternating courses of spandex typically
covered with polyamide and flat or textured polyamide. Alternate
course inclusive of polyamide can often lead to longer stitches.
ACPH allows for more flexibility on the use of polyamide, thus
making ACPH lower in cost. Further, ACPH can have a high shine or
glossy appearance. However, in sheer ACPH, garments are typically
less comfortable, row to row uniformity is lower and run resistance
is not possible with the known industrial techniques.
[0007] There is a need for lower cost hosiery garments with
improved comfort, gloss, flexibility on the use of polyamide or
other rigid yarn and/or run resistance.
SUMMARY OF THE INVENTION
[0008] An aspect of the present invention relates to a knitted
fabric prepared from a modified every course style which comprises
courses of spandex covered with rigid yarn and courses of bare
spandex plated with rigid yarn.
[0009] In one nonlimiting embodiment, the fabric is knit in a
repeating pattern comprising a course of spandex covered with rigid
yarn followed by a course of bare spandex plated with rigid
yarn.
[0010] In an alternative nonlimiting embodiment, the fabric is knit
in a pattern comprising two or more courses of spandex covered with
rigid yarn followed by a single course of bare spandex plated with
rigid yarn.
[0011] In yet another alternative nonlimiting embodiment, the
fabric is knit in a pattern comprising one or more courses of
spandex covered with rigid yarn followed by two or more courses of
bare spandex plated with rigid yarn.
[0012] In one nonlimiting embodiment, the rigid yarn comprises a
polyamide.
[0013] Another aspect of the present invention relates to a
garment, at least a portion of which is prepared from fabric having
a modified every course style which comprises courses of spandex
covered with rigid yarn and courses of bare spandex plated with
rigid yarn. In one nonlimiting embodiment, the garment is
hosiery.
[0014] Another aspect of the present invention relates to a method
for improving comfort and/or increasing gloss of an elastified
knitted fabric or garment thereof. The method comprises preparing
at least a portion of the garment from a fabric comprising courses
of spandex covered with rigid yarn and courses of bare spandex
plated with rigid yarn.
[0015] Yet another aspect of the present invention relates to a
method for lowering cost of an ECPH elastified knitted garment. The
method comprises preparing at least a portion of the garment from a
fabric comprising courses of spandex covered with rigid yarn and
courses of bare spandex plated with rigid yarn.
BRIEF DESCRIPTION OF THE FIGURES
[0016] FIGS. 1A-1C are diagrams comparing typical every course
panty hose construction (FIG. 1A), typical alternate course panty
hose construction (FIG. 1B) and a modified every course style of
the present invention comprising spandex covered with polyamide and
bare spandex plated with polyamide in every other course (FIG.
1C).
DETAILED DESCRIPTION OF THE INVENTION
[0017] Provided by this disclosure are fabrics prepared from a
modified every course style with courses of spandex covered with
rigid yarn and bare spandex plated with rigid yarn, elastified
knitted garments prepared from these fabrics and methods for
production of elastified knitted garments at lower cost and with
improved comfort, increased gloss, and/or in some embodiments
increased run resistance as compared to fabrics prepared from
traditional every course and/or alternative course styles.
[0018] By the term "spandex" as used herein it is also meant to be
inclusive of elastane and/or lycra.
[0019] By "traditional every course style" by which improvement in
gloss and/or run resistance and/or to which cost is compared for
purposes of the present disclosure, it is meant a fabric knit from
spandex covered with polyamide in every course.
[0020] By "traditional alternate course style" by which improvement
in comfort and/or run resistance is compared for purposes of the
present disclosure, it is meant a fabric knit from spandex covered
with polyamide or bare spandex plated with polyamide and polyamide
only in every other course.
[0021] By "plating" or "plated" for purposes of the present
disclosure, is it meant that the rigid yarn and the bare spandex
yarn are kept in a parallel, side-by-side relation throughout the
knit, with the relation between the two yarns controlled such that
the spandex material is always kept on one side of the rigid
yarn.
[0022] The fabrics of this disclosure are prepared from a modified
every course style as all courses are elastified and therefore
technically an ECPH with all its benefits in terms of comfort and
stretch.
[0023] One of the elastified courses of the fabrics of this
disclosure comprises a spandex covered with rigid yarn. The covered
spandex can be single covered, double covered or air jet covered.
Important advantages of using covered yarn in the fabrics of this
disclosure include, but are not limited to, a more natural soft
touch as compared with the plastic, slippery touch of spandex as
spandex is covered and not directly exposed to the skin and a
reduction in the fragility as compared to bare spandex.
[0024] The other elastified course of the fabrics of this
disclosure comprises bare spandex plated with rigid yarn. Any
spandex suitable for the fabrics of this disclosure can be used in
one nonlimiting embodiment, the spandex is fusible.
[0025] Any rigid yarn can be used in the present invention.
Nonlimiting examples may comprise polyamide, polyester or
polypropylene. In one nonlimiting embodiment, the rigid yarn is a
polyamide. Any polyamide can be used and, as will be understood by
the skilled artisan upon reading this disclosure, selection will
depend upon desired characteristics including, but not limited to,
brightness, bulk, uniformity, and gloss of the resulting
fabric.
[0026] Inclusion of the non covered, still elastified course in the
fabrics of this disclosure allows rigid yarn such as a polyamide to
shine as there are no turns to inhibit the shine. Accordingly, the
fabrics of this disclosure are higher in gloss as compared to
typical ECPH. Further, the negatives of the use of bare spandex in
a portion of the courses are mitigated by the other portion of the
course which are covered thereby providing for run resistant
garments with shine.
[0027] Various repeating patterns of the two elastified courses can
be used in the fabrics of this disclosure and selection may depend
upon the garment in which the fabric is being used and/or the
knitting pattern.
[0028] For example, FIG. 1C depicts a repeating pattern comprising
a course of spandex covered with rigid yarn followed by a course of
bare spandex plated with rigid yarn.
[0029] In an alternative nonlimiting embodiment, the fabric can be
knit in a repeating pattern comprising a single course of spandex
covered with rigid yarn followed by two or more courses of bare
spandex plated with rigid yarn.
[0030] In an alternative nonlimiting embodiment, the fabric can be
knit in a repeating pattern comprising two or more courses of
spandex covered with rigid yarn followed by a single course of bare
spandex plated with rigid yarn.
[0031] In hosiery, typically the number of feeds of distinct
courses are 4 and these can all be the same or different.
[0032] In seamless knitting, however, there are typically 8 feeds
while in circular knitting 32 or more feeds are used.
[0033] As will be understood by the skilled artisan upon reading
this disclosure, any of these patterns as well as alternative
patterns can be used in accordance with the present invention and
the invention is in no way limited to any particular repeating
pattern or number of courses of spandex covered with rigid yarn
followed by courses of bare spandex plated with rigid yarn.
[0034] In one nonlimiting embodiment, fabric is prepared by weft
knitting.
[0035] In one nonlimiting embodiment, other yarns are added to the
feeds to, for example, make the fabric heavier or to introduce
design, pattern and/or color to the fabric.
[0036] This disclosure also provides garment, at least a portion of
which is prepared from these fabrics having a modified every course
style comprising courses of spandex covered with rigid yarn and
courses of bare spandex plated with rigid yarn. In one nonlimiting
embodiment, the garment is a sheer garment. In one nonlimiting
embodiment, the garment has an 8 to 20-25 denier appearance. In one
nonlimiting embodiment, the garment is hosiery or intimate apparel.
In one nonlimiting embodiment for hosiery, the fabric of the
present invention may be used in the leg portion which the panty or
other sections may comprises fabrics with typical constructions. In
an alternative nonlimiting embodiment, the garment is
non-sheer.
[0037] Further provided by this disclosure are methods for
improving comfort, increasing gloss, and/or increasing run
resistance of an elastified knitted garment as well as methods for
lowering cost of an elastified knitted garment. These methods
comprise preparing the garment from at least a portion of fabric
comprising courses of spandex covered with rigid yarn and courses
of bare spandex plated with rigid yarn.
[0038] All patents, patent applications, test procedures, priority
documents, articles, blieations, manuals, and other documents cited
herein are fully incorporated by reference to the extent such
disclosure is not inconsistent with this invention and for all
jurisdictions in which such incorporation is permitted.
[0039] The following Example demonstrates the present invention and
its capability for use. The invention is capable of other and
different embodiments, and its several details are capable of
modifications in various apparent respects, without departing from
the scope and spirit of the present invention. Accordingly, the
Example is to be regarded as illustrative in nature and
nonlimiting.
Example
[0040] An elastified knitted garment was prepared by typical ECPH
wherein feed, 1, 2, 3 and 4 were 20 dtex fusible spandex
(LYCRA.RTM. fiber 777F) single covered with polyamide 6,6 flat,
bright 17 dtex 3 fil.
[0041] An elastified knitted garment was prepared using ECPH of the
present invention wherein feed 1 and 3 were 20 dtex fusible spandex
(LYCRA.RTM. fiber 777F) single covered with PA 6,6 flat, bright 17
dtex 3 fil and feed 2 and 4 were 20 dtex fusible spandex
(LYCRA.RTM. fiber 777F) bare, plated with PA 6,6 flat, bright.
[0042] Results of testing of these elastified knitted garments are
depicted in Table 1.
TABLE-US-00001 TABLE 1 Characteristic Typical ACPH Typical ECPH
ECPH of this disclosure Comfort level Mid High High
Shine/bright/glossy garment Possible Not possible Possible Row to
row uniformity Low High Mid Flexibility on polyamide use High Low
High Cost Low High Mid Run resistance Not possible Possible
Possible Layout/table presentation Large Small Mid Number of
elastified rows 2 of 4 4 of 4 4 of 4 EXAMPLES OF CONSTRUCTION
Feeder 1 Spandex/elastane Spandex/elastane covered Spandex/elastane
covered covered or plated with with polyamide with polyamide
polyamide Feeder 2 Polyamide only Spandex/elastane covered Bare
spandex/elastane with polyamide plated with polyamide Feeder 3
Spandex/elastane Spandex/elastane covered Spandex/elastane covered
covered or plated with with polyamide with polyamide polyamide
Feeder 4 Polyamide only Spandex/elastane covered Bare
spandex/elastane with polyamide plated with polyamide
* * * * *