Abstract:
A garment constructed by a cylinder knitting machine with a comfort quality area on or near the foot area, created by a different method of knitting from the rest of the tight. The difference between the quality of the leg and comfort portion of the garment (i.e., tights) consists of the use of a different needle movement and/or knitting tool, but is not limited to just that. Additionally, the fiber may also differ in the comfort area as compared to the leg area of the tights in order to reach different end results.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Patent Application No. 62/312,647, filed Mar. 24, 2016, the entire contents of which are incorporated by reference, as if fully set forth herein. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention generally relates to hosiery, and more specifically, to fashion tights with cushioned areas that are seamless. 
       BACKGROUND OF THE INVENTION 
       [0003]    Hosiery, such as fashion tights, are often uncomfortable due to the fact that they are constructed at a fine gauge, and do not provide adequate cushioning. For example, most fashion tights do not provide adequate padding in the heel and toe regions. 
         [0004]    In order to address this comfort issue, most existing hosiery have used “sewn-in” socks whereby two products (e.g., a tight and a sock) are sewn together. In many cases, tights and socks are constructed using two separate machines, making this process complicated. Tights with “sewn-in” socks also have many drawbacks. For one, there is a seamline where the tight-portion and the sock-portion come together. This seamline is uncomfortable for the user and is not aesthetically pleasing. Additionally, because tights with “sewn-in” socks require the use of at least two separate knitting machines, there is often a break in the manufacturing process (between the knitting of the tight and the sewing-in of the sock), resulting in wasted material, higher cost, added labor, longer development process and potentially causing delays in production. Moreover, because tights are typically made of fine gauge material, the process by which a sock is sewn into the tight may cause greater defects during the manufacturing process. 
         [0005]    Accordingly, there is presently a need for hosiery which provides comfort through a cushioned sock area, while also providing a fashionable look which is free from seamlines between the cushioned sock area and the rest of the hosiery. There is also a need for an efficient and streamlined process for producing such hosiery, which reduces the amount of wasted material, decreases labor and machine costs, and generates less defects. 
       SUMMARY OF THE INVENTION 
       [0006]    An exemplary embodiment of the present invention comprises a garment including at least one non-cushioned portion comprising a first stitch technique, and at least one cushioned portion comprising a second stitch technique such that the at least one non-cushioned portion and the at least one cushioned portion are seamlessly separated. The first stitch technique may be distinct from the second stitch technique and both the first stitch technique and the second stitch technique may be manufactured by a knitting machine having one or more cylinders. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    The invention will be better understood with reference to the following detailed description, of which the following drawings form an integral part. 
           [0008]      FIG. 1A  illustrates tights according to a first exemplary embodiment of the present invention. 
           [0009]      FIG. 1B  illustrates tights according to a second exemplary embodiment of the present invention. 
           [0010]      FIG. 1C  illustrates tights according to a third exemplary embodiment of the present invention. 
           [0011]      FIG. 2  illustrates a first cross section view of the tights shown in  FIG. 1B . 
           [0012]      FIG. 3  illustrates a second cross section view of the tights shown in  FIG. 1B . 
           [0013]      FIGS. 4A-4D  illustrate a needle and sinker diagram for a terry loop stitch used in connection with an exemplary embodiment of the present invention. 
           [0014]      FIG. 5  illustrates a stitch diagram for a terry loop stitch used in connection with an exemplary embodiment of the present invention. 
           [0015]      FIG. 6A  illustrates a stitch diagram for a tuck loop stitch used in connection with an exemplary embodiment of the present invention. 
           [0016]      FIG. 6B  illustrates a needle diagram for a tuck loop stitch used in connection with an exemplary embodiment of the present invention. 
           [0017]      FIG. 7A  illustrates a stitch diagram for a float loop stitch used in connection with an exemplary embodiment of the present invention. 
           [0018]      FIG. 7B  illustrates a needle diagram for a float loop stitch used in connection with an exemplary embodiment of the present invention. 
           [0019]      FIG. 8A  illustrates a detail view of a float loop stitch knitting technique for tights according to an exemplary embodiment of the present invention. 
           [0020]      FIG. 8B  illustrates a detail view of the float loop stitch knitting technique shown in  FIG. 8A  in a relaxed state. 
       
    
    
     DETAILED DESCRIPTION 
       [0021]    The present invention relates to hosiery and methods for making the same. In one exemplary embodiment, the hosiery includes a cushioned portion and a non-cushioned portion, each made using the same, or different, stitches. The cushioned and non-cushioned portions are preferably constructed so as to appear seamless. The cushioned are may be created by knitting a cushion pile in specific areas of the hosiery. 
         [0022]      FIG. 1A  illustrates a garment  100  according to a first exemplary embodiment of the present invention. In this embodiment, the garment  100  comprises hosiery (tights). This embodiment of the invention may be described as “ankle height” or “low bootie.” The garment  100  includes a non-cushioned portion  103 A, and a cushioned portion  101 A. As depicted the cushioned portion  103 A may extend from the user&#39;s toes to approximately the user&#39;s ankle. At the ankle the cushioned portion  103 A may meet the non-cushioned portion  101 A in a seamless transition. 
         [0023]      FIG. 1B  illustrates a garment  100 ′ according to a second exemplary embodiment of the present invention. In this embodiment, the garment  100 ′ comprises hosiery (tights). This embodiment of the invention may be described as “knee height” or “high boot.” The garment  100 ′ includes a cushioned portion  103 B, and a non-cushioned portion  101 B. As depicted the cushioned portion  103 B may extend from the user&#39;s toes to approximately the user&#39;s calf at a position below the knee. At the calf, the cushioned portion  103 B may meet the non-cushioned portion  101 B in a seamless transition. 
         [0024]      FIG. 1C  illustrates a garment  100 ″ according to a third exemplary embodiment of the present invention. In this embodiment, the garment  100 ″ comprises hosiery (tights). This embodiment of the invention may be described as a “foot bed.” The garment  100  includes a non-cushioned portion  101 C, and a cushioned portion  103 C. As depicted, the cushioned portion  103 C may extend along the sole of the user&#39;s foot. The cushioned portion  103 C may meet the non-cushioned portion  101 C in a seamless transition. In this exemplary embodiment, the cushioned portion  103 C may or may not be visible when the user is wearing shoes. 
         [0025]      FIG. 2  illustrates a first cross section view of a garment  200  according to a fourth exemplary embodiment of the present invention. In this embodiment the garment  200  comprises hosiery (tights). The garment  200  includes a non-cushioned portion  201 , and a cushioned portion  203 . As depicted, the cushioned portion  203  extends from the portion of the garment configured to cover a user&#39;s toes towards the user&#39;s upper legs until it meets the non-cushioned portion  201  of the garment positioned near the user&#39;s upper legs. In one exemplary embodiment, the materials (e.g., yarns) forming the cushioned  203  and non-cushioned  201  portions of the garment  200  have a fiber size up to 400 denier. 
         [0026]      FIG. 3  illustrates a cross section of the garment  200  shown in  FIG. 2 , taken along line A-A. As illustrated, the garment  200  has an interior side  301 , and an exterior side  303 . The interior side  301  faces the skin of the user and includes cushioned portion  203  and non-cushioned portion  201 . The exterior side  303  faces away from the user. From the exterior side  303 , the garment appears to be uniform with no visible delineation between the cushioned portion  203  and the non-cushioned portion  201  (i.e., seamless). This creates a garment  200  with a seamless, comfort transition (between the non-cushioned portion  201  and cushion portions  203 ) while using a continuous knitting process. As illustrated in  FIG. 3 , and as will be explained further below, the cushioned portion  203  of the garment may have a higher fabric ‘pile’ than the non-cushioned portion  201  of the garment. 
         [0027]    The cushioned and non-cushioned portions of the garments  100 ,  100 ′,  100 ″ and  200  may be constructed by a circular knitting machine of fine gauge. For example, fine gauge could be knitting machine with three hundred needles or more (i.e., 300N and above). Such a circular knitting machine may include one or more cylinders, as will be understood by those of ordinary skill in the art. The same circular knitting machine can be used to produce all parts of the garments  100 ,  100 ′,  100 ″ and  200 , including the cushioned ( 203 ,  103 A,  103 B,  103 C) and non-cushioned ( 201 ,  101 A,  101 B,  101 C) portions. Those of ordinary skill in the art will understand that while the exemplary embodiments described herein reference a circular knitting machine, any type of knitting machine may be utilized. 
         [0028]    The non-cushioned portion  201  of the garment  200  may be constructed using a flat knit stitch. In one exemplary embodiment, a circular knitting machine may have approximately four hundred (400) latch needles and a sinker configured for radial movement between the latch needles in order to form knit stitches. The cushioned portion  203  may be constructed using one of various types of cushioned stitches discussed further below. For example, the cushioned portion  203  may be formed using a terry loop stich ( 500 ;  FIG. 5 ), a tuck loop stitch ( 600 ;  FIG. 6A ), or a float loop stitch ( 700 ;  FIG. 7A ). In order to produce these two different stitches, the circular knitting machine may be programmed to transition from a regular knit stitch for the non-cushioned portion  201 , to one of the cushioned stitches for the cushioned portion  203 . In this way, a single machine may be used to manufacture the garment  200 . 
         [0029]    The circular knitting machine used to manufacture the garments  100 ,  100 ′,  100 ″ and  200  may have adjustable settings and/or be programmed to be able to transition from constructing the cushioned and non-cushioned portions of the garment. In one exemplary embodiment, the circular knitting machine does not have to be stopped while transitioning from constructing the cushioned to the non-cushioned portion of the garment. The needles and/or sinker may be adjusted in order to knit portions with various pile heights (and amount of cushion). The pile height may be increased by adjusting the knitting method, fiber type, additional brushing of the pile fibers post-knitting and the like. The cushioned portions ( 203 ,  103 A,  103 B,  103 C) of the garments ( 200 ,  100 ,  100 ′,  100 ″) may be constructed using elongated sinker loops or terry loop stitches, tuck loop stiches, and/or float loop stitches. Those of ordinary skill in the art will understand how to make various pile heights and cushioning for the cushioned portion of the garment  200  using the above-referenced techniques. The following U.S. Patents generally describing knitting techniques, circular knitting machines and the generation of piles are incorporated by reference herein: (1) U.S. Pat. No. 3,226,952; (2) U.S. Pat. No. 3,293,887; (3) U.S. Pat. No. 3,576,115; (4) U.S. Pat. No. 4,020,653; (5) U.S. Pat. No. 4,103,518; (6) U.S. Pat. No. 4,580,419; (7) U.S. Pat. No. 4,633,683; (8) U.S. Pat. No. 5,186,025; (9) U.S. Pat. No. 5,862,681, and (10) U.S. Pat. No. 6,089,047. 
         [0030]    To produce elongated sinker loop stitches or terry loop stitches, a body thread is knit into stiches in successive course, producing needle wales. The needle loops in each course are connected by sinker loops in turn producing sinker wales between the needle wales. A second thread of same size, composed of the body thread, is knitted into needle loops in each course. In one exemplary embodiment, the sinker loops for the second thread are elongated when compared to the sinker loops for the first thread. The elongated sinker threads protrude from the plane formed by the knitted item by forming a cushioned region on the face of the knitted item. More elongated sinker loops may be associated with longer terry loop stitches, in order to create the elongated sinker loops. 
         [0031]      FIGS. 4A-4D  show a needle and sinker diagram for an elongated sinker loop stitch including a first sinker  401 , and a second sinker  403 . One of the sinkers (e.g.,  401 ) may be configured to catch the main thread, and the other sinker (e.g.,  403 ) may be configured to catch a secondary thread. As illustrated, the first sinker  401  engages with a needle  407 . In one embodiment, the needle  407  may be a latch needle with a latch  409  and hook  413 . The hook  413  of the needle  407  may be operable to engage fibers  411 A of a base yarn, as shown in  FIG. 4B . The needle  407  also engages a needle loop  415  of a secondary yarn (as opposed to the base thread). The first sinker  401  may move in lateral directions  417 ,  419  towards and away from the needle  407 . The second sinker  403  may also move in a lateral direction  405 ,  406  towards and away from the needle  407 . When the two sinkers  401 ,  403  are moved in a lateral direction away from the needle  407  (i.e., ‘pulled back’), the shape of the second sinker  403  allows for an elongated loop thus creating a terry effect. The needle loops of the secondary yarn are connected by sinker loops as well. In one exemplary embodiment, the terry loops may be knit to only face one side of knit fabric, thereby creating a cushioned portion on only one side of the hosiery that is seamless from the opposite side. 
         [0032]    As shown in  FIG. 4B , the knitting process begins with the first and second sinkers  401 ,  403  relatively aligned in a horizontal direction (i.e., overlapping). Before the process begins, the second sinker  403  is moved laterally in a direction  405  away from the needle  407 . The fibers  411 A of the base yarn have yet to be contacted by the hook  413  of the needle  407 . As shown in  FIG. 4C , as the needle  407  moves down it catches the fibers  411 A of the base yarn in the hook  413 . At the same time, the first and second  401 ,  403  sinkers move laterally forward (in directions  417  and  406 , respectively) thereby allowing the fibers  411 A of the base yarn to catch on the protrusions of the sinkers, thus creating a base yarn loop  411 B. The needle loop  415  of a secondary yarn slides up the shaft of the needle  407  as the needle is moved downward, and engages with the base yarn loop  411 B, thereby creating a needle loop stitch  411 C (i.e., sinker loop stitch). As shown in  FIG. 4D , this needle loop stitch  411 C is removed from the first and second sinkers  401 ,  403  by the lateral movement of the first sinker  401  in a direction  419  away from the needle  407 . This process is repeated over and over again to create a sinker loop stitch which may be used to form the cushioned portion  203  of the garment  200 . As discussed further below, and as will be understood by those of ordinary skill in the art, various types of stitches may be used to form the cushioned portion  203  of the garment  200 , such as terry loop stitches, tuck loop stitches, and float loop stitches. 
         [0033]      FIG. 5  illustrates an stitch diagram for an exemplary terry loop stitch  500  formed by two sinkers. As depicted, the terry loop stitch  500  includes a needle loop  501 , a regular sinker loop  503 , and an elongated sinker loop  505 . The elongated sinker loop  505  may be longer than the regular sinker loop  503  and used to create a cushioned region for the garment  200 . 
         [0034]    The terry loop stitch  500  may be formed in much the same way as described above for the elongated sinker loop stitch ( FIGS. 4A-4D ). For example, a body thread/base yarn is knit into stitches in successive course, producing needle wales. The needle loops in each course are connected by sinker loops in turn producing sinker wales between the needle wales. A secondary yarn of the same size as the body thread/base yarn is knitted into needle loops in each course. These sinker loops for secondary yarn are elongated in correlation to body thread/base yarn sinker loops. Elongated sinker threads allow for thread to protrude from the plain of the fabric, in turn forming a cushioning on the face of the knitted item. The more the sinker loops elongate, the longer the loop you will have (in the form of terry loop stitches). To create elongated loops, there are two sinkers, one catching the main thread and the other catches the second thread and allows for longer loop. When the two sinkers pull back, the shape of the second sinker allows for a larger loop than typical sinker loops when creating another stitch, in turn creating the terry effect. The needle loops of the secondary yarn are connected by sinker loops as well. The terry loop stitches are knit to only face one side of the knit fabric, creating cushion that is seamless from the opposite side. 
         [0035]      FIG. 6A  illustrates an stitch diagram for an exemplary tuck loop stitch  600 .  FIG. 6B  illustrates a needle and sinker diagram for the tuck loop stitch  600 . As illustrated in  FIGS. 6A and 6B , the cushioned portion  203  of the garment  200  may also utilize a tuck loop stitch  600 . In such a tuck loop stitch  600 , specific needles may be configured to hold more than one stitch at a time, as shown in  FIG. 6B . 
         [0036]    As illustrated in  FIG. 6B , a needle  601  that is holding a loop  603  may receive a new loop  605  as the thread passes. The new loop  605  and the held loop  603  do not intermesh. Rather, the held loop  603  is tucked behind the new loop  605  on the reverse side of the stitch. When the held loop  603  is tucked behind the new loop  605  it creates double the thickness of a single loop, in turn creating extra thickness at the point of the stitch. The extra thickness may be used to provide the cushioning for the cushioned portion  203  of the garment  200 . 
         [0037]      FIG. 7A  illustrates a stitch diagram for an exemplary float loop stitch  700 .  FIG. 7B  illustrates a needle and sinker diagram for the float loop stitch  700 . In the exemplary float loop stitch  700 , a knitting stitch is composed of a held loop  703 , one or more float loops  701 , and knitted loops. The needle holding the held loop  703  does not receive a new loop as the thread passes. The float loop  701  falls to the back of the needle on the reverse side of the stitch and joins together the two nearest needle loops knitted from it. The float loops  701  may be composed of fiber types and filament yarn that is configured to create cushioning when the float stitch is allowed to return to its natural wavy shape, as is depicted in  FIGS. 8A and 8B . 
         [0038]      FIGS. 8A and 8B  illustrate further details of the float loop stitch  700 . In  FIG. 8A , a ‘2 by 2’ stitch pattern of float loop stitches  700  is illustrated.  FIG. 7A  above shows a ‘1 by 1’ stitch pattern of float loop stitches  700 . Those of ordinary skill in the art will realize that any pattern of float loop stitches  700  may be used to create the cushioned area  203  of the garment  200 , without departing from the scope of the present invention. 
         [0039]      FIG. 8A  shows the pattern of float loop stitches  700  in a ‘stretched’ state. When the fabric is allowed to ‘relax,’ the long strand of yarn  801  which stretches across each set of double loops bunches up a shown in  FIG. 8B . This bunching of the yarn fibers creates a cushion effect, by allowing the fibers of yarn to return to their natural state. The longer strands  801  are created when specific needles are allowed to rest in an inactive state during the knitting process. In the relaxed state, the yarn fibers of the longer strands  801  revert back to the ‘wavy’ nature shown in  FIG. 8B , and lose their ‘smooth’ appearance (as shown in  FIG. 8A ). The fibers of the longer strands  801  are knit with allowance to remain in a relaxed state, and thus create a fleece-like finish in the cushioned area  203  of the garment  200 . 
         [0040]    Although the invention has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly to include other variants and embodiments of the invention which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention. This disclosure is intended to cover any adaptations or variations of the embodiments discussed herein.